Dodge - Journey Fwd - Workshop Manual - 1985 - 1985

Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions Accessory Delay Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9 Accessory Delay Module: Electrical Diagrams Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10 Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Door Lock Relay Location Power Door Lock Relay: Locations Door Lock Relay Location Door Lock And Power Window Circuit Breaker And Relays Location The relay is located behind the dash panel, to the left of the glove box. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Door Lock Relay Location > Page 16 Power Door Lock Relay: Locations Electric Door Lock Relays Electric Door Lock Relay Location. Behind LH Side Of I/P Applicable to: 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 17 Power Door Lock Relay: Testing and Inspection To test the relay, move either of the front lock knobs to the lock and unlock positions. An audible clicking sound should be heard from under the dash near the steering column support. If the sound is heard while operating one knob but not the other, a defective switch or wiring may be at fault. If a clicking sound is not heard, locate the relay and test as follows: 1. Check for power by back probing the LG wire at the relay. ^ If power is present, go to step 2. ^ If power is not present, check the circuit breaker and the wire between the relay and the circuit breaker. 2. Back probe the OR wire at the relay and move the lock knob to the lock position. Battery voltage should be momentarily present, indicating that the relay operates in the lock position. ^ If power is present go to step 4. ^ If power is not present, go to step 3. 3. Backprobe the VT wire and move the lock knob to the lock position. ^ If power is present, the relay is defective. ^ If power is not present, the door switch or wiring may be defective. 4. Backprobe the LB wire at the relay and move the lock knob to the unlock position. Battery voltage should be momentarily present, indicating that the relay operates in the unlock position. ^ If power is present, the relay is operating properly. ^ If power is not present, go to step 5. 5. Backprobe the LG wire and move the lock knob to the unlock position. ^ If power is present, the relay is defective. ^ If power is not present, the door switch or wiring may be defective. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 18 Power Door Lock Relay: Service and Repair Door Lock And Power Window Circuit Breaker And Relays Location Disconnect the battery negative terminal. Remove the wire connector from the relay. Remove the attaching bolt that holds the relay to the instrument panel. Install by attaching relay to the instrument panel and connecting the wires to the relay. Connect the battery negative terminal and test the system for proper operation. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations Speed Control System Components LH Side Of Engine Compartment Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 29 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Power Module <--> [Electronic Spark Control Module] > Component Information > Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Power Module <--> [Electronic Spark Control Module] > Component Information > Locations > Page 33 Power Module: Description and Operation The spark control computer controls the air fuel ratio of the carburetor and the ignition timing. The computer receives signals from various sensors and processes them to determine the air fuel ratio of the carburetor and ignition timing. There are as many as six types of sensors which can be used to supply the spark control computer with the necessary information needed to fire the spark plugs at the precise moment and, with the feedback carburetor, change the air-fuel ratio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 42 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 43 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 44 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 45 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 46 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 47 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 48 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 49 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 50 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 51 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 52 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 53 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 54 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 55 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 56 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock Technical Service Bulletin # 181985A Date: 851201 Fuel System - Vapor Lock Models 1981-1985 Van & Wagon Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 20, 1985 No. 18-19-85 REVISION A P-4782-C This bulletin supersedes Technical Service Bulletin #18-19-85 which should be removed from your files. The model application has been expanded to include 1981 and 1982 model years. SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING TWO PART NUMBERS: Vapor Lock Package With 22 Gallon Fuel Tank PN 4397611 Vapor Lock Package With 36 Gallon Fuel Tank PN 4397612 ADDITIONAL PARTS INFORMATION ON NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 All vehicles equipped with dual air conditioning, without electrically heated rear window defroster, and with 60 amp alternator must order the following package in addition to the vapor lock package. If vehicle is equipped with a 114 amp alternator, do not order this package or make any changes to the charging system. 1 78 AMP Alternator Package PN 4397615 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 61 Refer to parts list for contents of each package. Must be ordered separately: 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. REPAIR PROCEDURE A.Engine Compartment Harness Pn 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1A - ENGINE COMPARTMENT WIRING 3. Remove engine cover. Install the bare eyelet terminal of overlay harness, PN 4362295, to the negative terminal of the ignition coil as shown in Figure 1-A. FIGURE 1B - ENGINE COMPARTMENT WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 62 4. Route and secure the engine overlay harness, PN 4362295, along the existing main engine wiring harness using the existing wiring clips and two tie wraps, PN 6015756 (Figure 1-B). FIGURE 1C - ENGINE COMPARTMENT WIRING 5. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness to the bulkhead connector using the existing wiring clips and three tie wraps, PN 6015756 (Figure 1-C). Loop and tape any excess wire of the engine overlay harness. FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 6. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar multi-purpose grease PN 4318063, and snap into cavity #14 of the engine side of the bulkhead connector (Figure 1-D). B.Instrument Panel Harnesses Pn 4362289, All Models Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 63 FIGURE 2A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) 1. Remove instrument panel left lower trim panel. 2. Insert two bare terminals from instrument panel overlay harness, PN 4362289, into the instrument panel side of the bulkhead connector (Figure 2-A). a. Gray with black tracer wire into cavity #14. b. Dark green wire into cavity #13. INSTRUMENT PANEL WIRING 3. Secure bare eyelet ground terminal (white with black tracer wire) from instrument panel overlay harness, PN 4362289, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). NOTE: CERTAIN VEHICLES ARE ALREADY EQUIPPED WITH THE GROUND SCREW. IF SO, DISCARD THE SUPPLIED SCREW. FIGURE 2C - INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 64 FIGURE 2D - INSTRUMENT PANEL WIRING 4. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-C). Install the extracted terminal (orange wire) into the natural colored 1-way connector supplied with instrument panel overlay harness, PN 4362289. Install the bare terminal (orange wire) from the instrument panel overlay harness, PN 4362289, into the vacated cavity in the ignition switch connector. Reconnect the natural colored 1-way connectors supplied with the instrument panel overlay harness, PN 4362289, and reconnect the ignition switch connectors (Figure 2-C and 2-D). FIGURE 2E - TYPICAL CONTROL MODULE MOUNTING 5. Connect the control (auto shut-down) module, PN 5226640, to the natural colored 8-way connector from instrument panel overlay harness, PN 4362289. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 65 FIGURE 2D - INSTRUMENT PANEL WIRING FIGURE 2F - INSTRUMENT PANEL WIRING 6. Route the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289, to the back of the brake bracket for mating in a later step (Figures 2-B, 2-D, and 2-F). Secure instrument panel overlay harness, PN 4362289, using tie wrap, PN 6015756, to keep it clear of any possible interferences. Only one of the following installation procedures (Step 7) will be used. Take notice of which one applies to the vehicle being repaired. 7. Without Auxiliary Air Conditioning and/or Heater - Jumper Harness PN 4362291 a. Remove instrument panel hood and bezel assembly and remove radio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 66 FIGURE 2D - INSTRUMENT PANEL WIRING b. Route instrument panel jumper harness, PN 4362291, from the back of the brake bracket to the existing 3-way red molded connector. Secure by using existing wiring clips (Figure 2-D). c. Insert the bare bullet terminal (black with white tracer wire) from instrument panel jumper harness, PN 4362291, into the existing 3-way red molded connector from the main instrument panel wiring harness (Figure 2-D). d. Mate the orange colored 1-way connector from instrument panel jumper harness, PN 4362291, to the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). e. Reinstall instrument panel hood and bezel assembly and install radio. FIGURE 2F - INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater and Power Windows - Jumper Harness PN 4362292 a. Disconnect from each other, the two existing brown colored 1-way connectors located near the left instrument panel vent (Figure 2-F). Reconnect these two brown colored 1-way connectors to the two brown colored 1-way connectors from instrument panel jumper harness, PN 4362292 (Figure 2-F). b. Mate the orange colored 1-way connector from the instrument panel jumper harness, PN 4362292, to the orange colored 1-way connector from instrument panel overlay harness, PN 4362289 (Figure 2-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 67 INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater Without Power Windows - Relay Harness PN 4362290 a. Remove instrument panel hood and bezel assembly. Remove radio. b. Install the ignition switch protection relay, PN 4162597, to the back of the brake bracket (mounting location shown in Figure 2-B) and attach instrument panel relay harness, PN 4362290, to relay. c. Secure bare eyelet ground terminal (white wire) from instrument panel relay harness, PN 4362290, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING d. Route the dark blue wire from the instrument panel relay harness, PN 4362290 to the existing 3-way red molded connector using existing wiring clips. Insert bullet terminal (dark blue wire) into red molded connector (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 68 INSTRUMENT PANEL WIRING e. Insert bare bullet terminal (red wire) from instrument panel relay harness, PN 4362290, into the existing 3-way yellow molded connector from the main instrument panel wiring harness (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING f. Mate the orange colored 1-way connector from instrument panel relay harness, PN 4362290, to the colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). g. Install the instrument panel left lower trim panel, instrument panel hood, bezel assembly and radio. C.In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Feed red and yellow molds of body wiring harness, PN 4362293, through slot in the crossmember. Remove existing screw for gauge unit ground. Install eyelet terminal of harness, PN 4362293 (and ground eyelet terminal of 36 gallon tank gauge/pump unit) and torque ground screw to 36 inch pounds. CAUTION: GROUND SCREW MUST BE TIGHTENED SECURELY TO OPERATE ELECTRIC PUMP AND GAUGE UNIT. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 69 FIGURE 3A - BODY WIRING FIGURE 3B - BODY WIRING Install red mold of body harness, PN 4362293, onto red stud of gauge/pump unit. Install yellow mold of harness, PN 4362293, onto black stud of gauge/pump unit (figure 3-a or 3-b). Install molded blade terminal of harness, PN 4362293, onto blade terminal of 22 gallon gauge unit only. NOTE: PREVIOUS GAUGE UNIT GROUND WILL NOT BE USED ON 22 GALLON GAUGE/PUMP UNIT. ON 36 GALLON GAUGE PUMP UNIT, THE GROUND WIRE ON HARNESS PN 4362293 WILL NOT BE USED. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. Set aside the rest of harness, PN 4362293, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. D.Body Wiring Harness Pn 4362293 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 70 FIGURE 3C - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 71 FIGURE 3-F - BODY WIRING 1. Vehicles With 36 Gallon Tank Route harness, PN 4362293, to the right (passenger) side of vehicle along the fuel line tubes and tie wrap (1). At right frame rail, route harness forward to next crossmember (Figures 3-C and 3-E). Tie wrap harness in three (3) places. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 72 FIGURE 3D - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 73 FIGURE 3-F - BODY WIRING Vehicles With 22 Gallon Tank Route harness, PN 4362293, along right frame rail following brake lines (Figures 3-D and 3-E). Tie wrap in two (2) places. NOTE: HARNESS MUST BE ABOVE SHOCK STRUT WITH EITHER 36 OR 22 GALLON TANK. 2. At crossmember, route harness to the left rail following existing brake lines and tie wrap in two (2) places. At left rail, route harness forward through access holes following existing brake lines. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 74 FIGURE 3-F - BODY WIRING NOTE: HARNESS SHOULD BE TIGHT IN THIS AREA THE WRAP IN FOUR (4) PLACES (FIGURE 3-E). 3. At engine compartment, route harness through existing speedometer cable clips to bulkhead connector. If excess wiring exists; loop, tie wrap (2), and install into existing clip (Figure 3-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 75 FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 4. Plug bare terminal of harness, PN 4362293, into cavity #13 of the bulkhead connector (Figure 1-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 76 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 77 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 78 FIGURE 9 - ELECTRIC FUEL PUMP WIRING DIAGRAMW/AUX A/C & HEATER-W/O POWER WINDOWS 5. For all vehicles except those which require a 78 amp alternator package: Reinstall instrument panel side, then engine compartment side of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURES 7, 8, OR 9 FOR OVERALL WIRING DIAGRAMS. E.Engine Compartment Fuel Reservoir/Filter Lnstallation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 79 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER 1. Using template, PN 4418011, mark and drill (from engine side of passenger side chassis rail) two (2) holes .290" diameter (L size drill) as shown in Figure 4-A. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 80 FIGURE 4B - Mounting Fuel Resevoir/Filter 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. NOTE: RUBBER SPLASH SHIELD MAY HAVE TO BE CUT OUT AROUND FUEL RESERVOIR. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube, PN 4306968 (Figure 4-B). 4. Install return hose assembly, PN 4418006, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end (Figure 4-B). 5. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 42O3576. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 81 FIGURE 4B - Mounting Fuel Resevoir/Filter 6. Install one 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the fuel pump outlet tube to the reservoir/filter inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). 7. Install the other 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 8. Tighten all hose clamps to 10 inch pounds. FIGURE 10 9. Type Authorized Modification Label, PN 4275086, as shown in Figure 10 and attach near VECI label. 10. For all models except 1981-1984 equipped with Carter Thermoquad 4BBL carburetor or dual air conditioning units without electrically Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 82 heated rear window defroster. Reconnect battery. Start the engine, and inspect the entire system for fuel leaks and proper wire and hose routing. 11. Reinstall engine cover. F.1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (Pn 4397 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6O22254, (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT, AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6O22254. THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 83 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference with nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose-to-regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. For all models except those equipped with dual air conditioning units, without electrically heated rear window defroster and with 60 amp alternator: 6. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 7. Reinstall engine cover. G.Vehicles Equipped With Dual Air Conditioning Units, Without Electrically Heated Rear Defroster, and With 60 Amp Alternator. I Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 84 HEADLAMP AND DASH WIRING ASSEMBLY 1. Disconnect the battery positive lead (single in-line connection) from the headlamp and dash wiring assembly (Figure 6-A). FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 2. Remove the following wires from the engine compartment side of the bulkhead connector (Figure 6-B). a. Red wire from cavity #39 (ammeter). b. Black wire from cavity #33 (ammeter). Cut off the terminals and wrap tape around each end of both wires to insure that shorting cannot occur. Then tape the wrapped wires back against the main harness. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 85 FIGURE 6-C - 78 AMP ALTERNATOR WIRING 3. Remove the alternator output wire (heavy gauge) from the 60 amp alternator (Figure 6-C). Cut the wire off leaving approximately three (3) inches of wire extending out of the main harness. Tape the end of the lead thoroughly. Then fold and tape the lead back against the main harness to prevent shorting. 4. Remove 60 amp alternator assembly and install 78 amp alternator assembly, PN 4111204, per the service manual alternator replacement procedure. HEADLAMP AND DASH WIRING ASSEMBLY Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 86 FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 5. Beginning at the bulkhead, route and connect the wiring assembly, PN 4362343, as shown in Figure 6-A. Use the existing clip for main harness and tie wrap with three (3) tie wraps, PN 6015756. Insert the two bare terminals from alternator overlay wiring harness, PN 4362343, as shown in Figure 6-B as follows: NOTE: THE 4362343 ALTERNATOR OVERLAY HARNESS WAS MANUFACTURED WITH THE RED AND BLACK WIRES REVERSED. THEREFORE, IT WILL BE NECESSARY TO INSTALL THE BLACK WIRE (LABELED RED) INTO CAVITY #39 (RED WIRE PREVIOUSLY REMOVED), AND THE RED WIRE (LABELED BLACK) INTO CAVITY #33 (BLACK WIRE PREVIOUSLY REMOVED). FAILURE TO REVERSE THESE TWO WIRES WILL RESULT IN THE AMMETER SHOWING THE OPPOSITE CHARGE INDICATION. a. Red wire into cavity #33 (ammeter) - (labeled as black wire). b. Black wire into cavity #39 (ammeter) - (labeled as red wire). 6. Install wiring assembly, PN 4362343, alternator output terminal to new 78 amp alternator. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 87 FIGURE 6A1 7. Connect the battery positive lead and the headlamp and dash wiring assembly lead to those of the alternator overlay wiring assembly, PN 4362343, as shown in circled view of Figure 6-A. 8. Reinstall instrument panel half, then engine compartment half of bulkhead connector and torque to 40 inch pounds. 9. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 10. Reinstall engine cover. POLICY: Reimbursable within the provisions of the warranty and repair manual. TIME ALLOWANCE: Labor Operation No. 14-70-17-94 - All 2.5 Hrs. Optional Equipment: 14-70-17-60 - Carter Thermoquad Carburetor 0.5 Hrs. 14-70-17-61 - With Auxiliary A/C - Without Elec. 0.7 Hrs. Rear Window Defroster 14-70-17-62 - Without Auxiliary A/C 0.3 Hrs. 14-70-17-63 - With Auxiliary A/C - Without 0.4 Hrs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 88 Power Windows FAILURE CODE: AM - Authorized Modification Part List VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 22 GALLON FUEL TANK PACKAGE PART NO. 4397611 QTY PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075432 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Seal - Fuel Tank Gauge 3404451 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 36 GALLON FUEL TANK PACKAGE PART NO. 4397612 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075436 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Gasket - Fuel Tank Sending Unit 4115209 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 89 *It may be necessary to order clamp separately on early released packages. PARTS LIST FUEL PRESSURE REGULATOR PACKAGE FOR 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO.4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 PARTS LIST 78 AMP ALTERNATOR PACKAGE FOR 1981-1985 B MODEL TRUCKS WITH 5.2L OR 5.9L ENGINES PACKAGE PART NO. 4397615 QTY. PART NAME PART NO. 1 78 AMP Alternator Assembly - Complete 4111204 1 Alternator Overlay Wiring Harness 4362343 4 Tie Wrap 6015756 1 Gasket - Bulkhead Connector 4055399 FIGURE 4B - Mounting Fuel Resevoir/Filter 1. Fuel Filter/ Reservoir - 4418012 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 90 2. Screw - Self Tapping - 6022777 (2 Req.) 3. Tube Assy - Fuel Pump to Reservoir - 4306968 4. Return Hose & Sleeve Assy - 4418006 5. Hose Clamps - 6500650 (2 Req.) - 1/4" 6. Hose-Fuel Pump Outlet to Reservoir Inlet - 4203576 7. Hose-Reservoir Outlet to Carburetor or Regulator Fuel Tube - 4203576 8. Hose Clamps - 6500651 (4 Req.) - 5/16" Included but not shown: 2 piece Convolute Tubing - 4279993 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1 SCREW & WASHER - 6022254 2 REGULATOR BRACKET - 4418010 3 REGULATOR - 4418OD9 4 TUBE - REGULATOR TO CARB - 4418008 5 TUBE - RESERVOIR HOSE TO REGULATOR - 4418014 6 SCREW (2 EA.) - REGULATOR TO BRACKET - 6033066 7 CLAMP (5116) - 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 182985 > Jun > 85 > ECM - Warm Surge At Steady Speed Powertrain Control Module: Customer Interest ECM - Warm Surge At Steady Speed Models 1985 Trucks Equipped With 5.2L-2BBL Engine, O2 Feedback Carburetor System & Automatic Transmission With California Emissions Package Subject Warm Surge at Steady Speed Index DRIVEABILITY Date June 24, 1985 No.. 18-29-85 SYMPTOM/CONDITION Vehicle will exhibit a surge at steady speeds with engine at full operating temperature. PARTS REQUIRED Driveability Package PN 4397618 Contains: 1 Vacuum Delay Valve PN 4173433 1 Hose Routing Label PN 4179843 Must be ordered separately: 1 ESA Module PN 4289977 1 CVSCC PN 4095231 1 Authorized Modification Label PN 4275086 REPAIR PROCEDURE 1. Remove existing ESA module (PN 4289637) and install supplied ESA module, PN 4289977. 2. Drain coolant and remove existing CVSCC (coolant vacuum switch cold closed) and install supplied CVSCC, PN 4095231. 3. Cut one 1-1/2" section of 3/16" vacuum hose, PN 4105167 (serviced in 50 foot rolls). 4. Install the 1-1/2" section of 3/16" hose on the natural colored end of the vacuum delay valve, PN 4173433, supplied in package. 5. The EGR solenoid is mounted on the fender shield (right side of engine compartment). It can be identified by a "white" right angle vacuum connector. Remove the white right angle vacuum connector on the EGR solenoid and install the delay valve assembly on the EGR solenoid. The 1-1/2" piece of 3/16" hose is attached in place of the removed white right angle connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 182985 > Jun > 85 > ECM - Warm Surge At Steady Speed > Page 95 FIGURE 1 - Vacuum Delay Valve - Attachment Procedure The white right angle connector is then attached to the orange colored side of the vacuum delay valve (Figure 1). 6. Wipe existing hose routing label clean. Install hose routing label, PN 4179843, supplied in package over the original label. FIGURE 2 7. Type Authorized Modification Label, PN 4275086, as shown in Figure 2 and install next to the VECI label. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 08-15-61-90 Trucks 0.5 Hrs. Vans 0.6 Hrs. FAILURE CODE: AM - Authorized Modification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 101 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 102 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 103 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 104 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 105 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 106 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 107 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 108 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 109 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 110 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 111 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 112 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 113 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 114 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 115 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock Technical Service Bulletin # 181985A Date: 851201 Fuel System - Vapor Lock Models 1981-1985 Van & Wagon Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 20, 1985 No. 18-19-85 REVISION A P-4782-C This bulletin supersedes Technical Service Bulletin #18-19-85 which should be removed from your files. The model application has been expanded to include 1981 and 1982 model years. SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING TWO PART NUMBERS: Vapor Lock Package With 22 Gallon Fuel Tank PN 4397611 Vapor Lock Package With 36 Gallon Fuel Tank PN 4397612 ADDITIONAL PARTS INFORMATION ON NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 All vehicles equipped with dual air conditioning, without electrically heated rear window defroster, and with 60 amp alternator must order the following package in addition to the vapor lock package. If vehicle is equipped with a 114 amp alternator, do not order this package or make any changes to the charging system. 1 78 AMP Alternator Package PN 4397615 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 120 Refer to parts list for contents of each package. Must be ordered separately: 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. REPAIR PROCEDURE A.Engine Compartment Harness Pn 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1A - ENGINE COMPARTMENT WIRING 3. Remove engine cover. Install the bare eyelet terminal of overlay harness, PN 4362295, to the negative terminal of the ignition coil as shown in Figure 1-A. FIGURE 1B - ENGINE COMPARTMENT WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 121 4. Route and secure the engine overlay harness, PN 4362295, along the existing main engine wiring harness using the existing wiring clips and two tie wraps, PN 6015756 (Figure 1-B). FIGURE 1C - ENGINE COMPARTMENT WIRING 5. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness to the bulkhead connector using the existing wiring clips and three tie wraps, PN 6015756 (Figure 1-C). Loop and tape any excess wire of the engine overlay harness. FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 6. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar multi-purpose grease PN 4318063, and snap into cavity #14 of the engine side of the bulkhead connector (Figure 1-D). B.Instrument Panel Harnesses Pn 4362289, All Models Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 122 FIGURE 2A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) 1. Remove instrument panel left lower trim panel. 2. Insert two bare terminals from instrument panel overlay harness, PN 4362289, into the instrument panel side of the bulkhead connector (Figure 2-A). a. Gray with black tracer wire into cavity #14. b. Dark green wire into cavity #13. INSTRUMENT PANEL WIRING 3. Secure bare eyelet ground terminal (white with black tracer wire) from instrument panel overlay harness, PN 4362289, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). NOTE: CERTAIN VEHICLES ARE ALREADY EQUIPPED WITH THE GROUND SCREW. IF SO, DISCARD THE SUPPLIED SCREW. FIGURE 2C - INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 123 FIGURE 2D - INSTRUMENT PANEL WIRING 4. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-C). Install the extracted terminal (orange wire) into the natural colored 1-way connector supplied with instrument panel overlay harness, PN 4362289. Install the bare terminal (orange wire) from the instrument panel overlay harness, PN 4362289, into the vacated cavity in the ignition switch connector. Reconnect the natural colored 1-way connectors supplied with the instrument panel overlay harness, PN 4362289, and reconnect the ignition switch connectors (Figure 2-C and 2-D). FIGURE 2E - TYPICAL CONTROL MODULE MOUNTING 5. Connect the control (auto shut-down) module, PN 5226640, to the natural colored 8-way connector from instrument panel overlay harness, PN 4362289. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 124 FIGURE 2D - INSTRUMENT PANEL WIRING FIGURE 2F - INSTRUMENT PANEL WIRING 6. Route the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289, to the back of the brake bracket for mating in a later step (Figures 2-B, 2-D, and 2-F). Secure instrument panel overlay harness, PN 4362289, using tie wrap, PN 6015756, to keep it clear of any possible interferences. Only one of the following installation procedures (Step 7) will be used. Take notice of which one applies to the vehicle being repaired. 7. Without Auxiliary Air Conditioning and/or Heater - Jumper Harness PN 4362291 a. Remove instrument panel hood and bezel assembly and remove radio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 125 FIGURE 2D - INSTRUMENT PANEL WIRING b. Route instrument panel jumper harness, PN 4362291, from the back of the brake bracket to the existing 3-way red molded connector. Secure by using existing wiring clips (Figure 2-D). c. Insert the bare bullet terminal (black with white tracer wire) from instrument panel jumper harness, PN 4362291, into the existing 3-way red molded connector from the main instrument panel wiring harness (Figure 2-D). d. Mate the orange colored 1-way connector from instrument panel jumper harness, PN 4362291, to the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). e. Reinstall instrument panel hood and bezel assembly and install radio. FIGURE 2F - INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater and Power Windows - Jumper Harness PN 4362292 a. Disconnect from each other, the two existing brown colored 1-way connectors located near the left instrument panel vent (Figure 2-F). Reconnect these two brown colored 1-way connectors to the two brown colored 1-way connectors from instrument panel jumper harness, PN 4362292 (Figure 2-F). b. Mate the orange colored 1-way connector from the instrument panel jumper harness, PN 4362292, to the orange colored 1-way connector from instrument panel overlay harness, PN 4362289 (Figure 2-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 126 INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater Without Power Windows - Relay Harness PN 4362290 a. Remove instrument panel hood and bezel assembly. Remove radio. b. Install the ignition switch protection relay, PN 4162597, to the back of the brake bracket (mounting location shown in Figure 2-B) and attach instrument panel relay harness, PN 4362290, to relay. c. Secure bare eyelet ground terminal (white wire) from instrument panel relay harness, PN 4362290, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING d. Route the dark blue wire from the instrument panel relay harness, PN 4362290 to the existing 3-way red molded connector using existing wiring clips. Insert bullet terminal (dark blue wire) into red molded connector (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 127 INSTRUMENT PANEL WIRING e. Insert bare bullet terminal (red wire) from instrument panel relay harness, PN 4362290, into the existing 3-way yellow molded connector from the main instrument panel wiring harness (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING f. Mate the orange colored 1-way connector from instrument panel relay harness, PN 4362290, to the colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). g. Install the instrument panel left lower trim panel, instrument panel hood, bezel assembly and radio. C.In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Feed red and yellow molds of body wiring harness, PN 4362293, through slot in the crossmember. Remove existing screw for gauge unit ground. Install eyelet terminal of harness, PN 4362293 (and ground eyelet terminal of 36 gallon tank gauge/pump unit) and torque ground screw to 36 inch pounds. CAUTION: GROUND SCREW MUST BE TIGHTENED SECURELY TO OPERATE ELECTRIC PUMP AND GAUGE UNIT. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 128 FIGURE 3A - BODY WIRING FIGURE 3B - BODY WIRING Install red mold of body harness, PN 4362293, onto red stud of gauge/pump unit. Install yellow mold of harness, PN 4362293, onto black stud of gauge/pump unit (figure 3-a or 3-b). Install molded blade terminal of harness, PN 4362293, onto blade terminal of 22 gallon gauge unit only. NOTE: PREVIOUS GAUGE UNIT GROUND WILL NOT BE USED ON 22 GALLON GAUGE/PUMP UNIT. ON 36 GALLON GAUGE PUMP UNIT, THE GROUND WIRE ON HARNESS PN 4362293 WILL NOT BE USED. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. Set aside the rest of harness, PN 4362293, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. D.Body Wiring Harness Pn 4362293 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 129 FIGURE 3C - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 130 FIGURE 3-F - BODY WIRING 1. Vehicles With 36 Gallon Tank Route harness, PN 4362293, to the right (passenger) side of vehicle along the fuel line tubes and tie wrap (1). At right frame rail, route harness forward to next crossmember (Figures 3-C and 3-E). Tie wrap harness in three (3) places. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 131 FIGURE 3D - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 132 FIGURE 3-F - BODY WIRING Vehicles With 22 Gallon Tank Route harness, PN 4362293, along right frame rail following brake lines (Figures 3-D and 3-E). Tie wrap in two (2) places. NOTE: HARNESS MUST BE ABOVE SHOCK STRUT WITH EITHER 36 OR 22 GALLON TANK. 2. At crossmember, route harness to the left rail following existing brake lines and tie wrap in two (2) places. At left rail, route harness forward through access holes following existing brake lines. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 133 FIGURE 3-F - BODY WIRING NOTE: HARNESS SHOULD BE TIGHT IN THIS AREA THE WRAP IN FOUR (4) PLACES (FIGURE 3-E). 3. At engine compartment, route harness through existing speedometer cable clips to bulkhead connector. If excess wiring exists; loop, tie wrap (2), and install into existing clip (Figure 3-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 134 FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 4. Plug bare terminal of harness, PN 4362293, into cavity #13 of the bulkhead connector (Figure 1-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 135 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 136 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 137 FIGURE 9 - ELECTRIC FUEL PUMP WIRING DIAGRAMW/AUX A/C & HEATER-W/O POWER WINDOWS 5. For all vehicles except those which require a 78 amp alternator package: Reinstall instrument panel side, then engine compartment side of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURES 7, 8, OR 9 FOR OVERALL WIRING DIAGRAMS. E.Engine Compartment Fuel Reservoir/Filter Lnstallation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 138 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER 1. Using template, PN 4418011, mark and drill (from engine side of passenger side chassis rail) two (2) holes .290" diameter (L size drill) as shown in Figure 4-A. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 139 FIGURE 4B - Mounting Fuel Resevoir/Filter 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. NOTE: RUBBER SPLASH SHIELD MAY HAVE TO BE CUT OUT AROUND FUEL RESERVOIR. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube, PN 4306968 (Figure 4-B). 4. Install return hose assembly, PN 4418006, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end (Figure 4-B). 5. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 42O3576. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 140 FIGURE 4B - Mounting Fuel Resevoir/Filter 6. Install one 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the fuel pump outlet tube to the reservoir/filter inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). 7. Install the other 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 8. Tighten all hose clamps to 10 inch pounds. FIGURE 10 9. Type Authorized Modification Label, PN 4275086, as shown in Figure 10 and attach near VECI label. 10. For all models except 1981-1984 equipped with Carter Thermoquad 4BBL carburetor or dual air conditioning units without electrically Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 141 heated rear window defroster. Reconnect battery. Start the engine, and inspect the entire system for fuel leaks and proper wire and hose routing. 11. Reinstall engine cover. F.1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (Pn 4397 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6O22254, (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT, AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6O22254. THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 142 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference with nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose-to-regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. For all models except those equipped with dual air conditioning units, without electrically heated rear window defroster and with 60 amp alternator: 6. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 7. Reinstall engine cover. G.Vehicles Equipped With Dual Air Conditioning Units, Without Electrically Heated Rear Defroster, and With 60 Amp Alternator. I Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 143 HEADLAMP AND DASH WIRING ASSEMBLY 1. Disconnect the battery positive lead (single in-line connection) from the headlamp and dash wiring assembly (Figure 6-A). FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 2. Remove the following wires from the engine compartment side of the bulkhead connector (Figure 6-B). a. Red wire from cavity #39 (ammeter). b. Black wire from cavity #33 (ammeter). Cut off the terminals and wrap tape around each end of both wires to insure that shorting cannot occur. Then tape the wrapped wires back against the main harness. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 144 FIGURE 6-C - 78 AMP ALTERNATOR WIRING 3. Remove the alternator output wire (heavy gauge) from the 60 amp alternator (Figure 6-C). Cut the wire off leaving approximately three (3) inches of wire extending out of the main harness. Tape the end of the lead thoroughly. Then fold and tape the lead back against the main harness to prevent shorting. 4. Remove 60 amp alternator assembly and install 78 amp alternator assembly, PN 4111204, per the service manual alternator replacement procedure. HEADLAMP AND DASH WIRING ASSEMBLY Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 145 FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 5. Beginning at the bulkhead, route and connect the wiring assembly, PN 4362343, as shown in Figure 6-A. Use the existing clip for main harness and tie wrap with three (3) tie wraps, PN 6015756. Insert the two bare terminals from alternator overlay wiring harness, PN 4362343, as shown in Figure 6-B as follows: NOTE: THE 4362343 ALTERNATOR OVERLAY HARNESS WAS MANUFACTURED WITH THE RED AND BLACK WIRES REVERSED. THEREFORE, IT WILL BE NECESSARY TO INSTALL THE BLACK WIRE (LABELED RED) INTO CAVITY #39 (RED WIRE PREVIOUSLY REMOVED), AND THE RED WIRE (LABELED BLACK) INTO CAVITY #33 (BLACK WIRE PREVIOUSLY REMOVED). FAILURE TO REVERSE THESE TWO WIRES WILL RESULT IN THE AMMETER SHOWING THE OPPOSITE CHARGE INDICATION. a. Red wire into cavity #33 (ammeter) - (labeled as black wire). b. Black wire into cavity #39 (ammeter) - (labeled as red wire). 6. Install wiring assembly, PN 4362343, alternator output terminal to new 78 amp alternator. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 146 FIGURE 6A1 7. Connect the battery positive lead and the headlamp and dash wiring assembly lead to those of the alternator overlay wiring assembly, PN 4362343, as shown in circled view of Figure 6-A. 8. Reinstall instrument panel half, then engine compartment half of bulkhead connector and torque to 40 inch pounds. 9. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 10. Reinstall engine cover. POLICY: Reimbursable within the provisions of the warranty and repair manual. TIME ALLOWANCE: Labor Operation No. 14-70-17-94 - All 2.5 Hrs. Optional Equipment: 14-70-17-60 - Carter Thermoquad Carburetor 0.5 Hrs. 14-70-17-61 - With Auxiliary A/C - Without Elec. 0.7 Hrs. Rear Window Defroster 14-70-17-62 - Without Auxiliary A/C 0.3 Hrs. 14-70-17-63 - With Auxiliary A/C - Without 0.4 Hrs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 147 Power Windows FAILURE CODE: AM - Authorized Modification Part List VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 22 GALLON FUEL TANK PACKAGE PART NO. 4397611 QTY PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075432 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Seal - Fuel Tank Gauge 3404451 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 36 GALLON FUEL TANK PACKAGE PART NO. 4397612 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075436 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Gasket - Fuel Tank Sending Unit 4115209 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 148 *It may be necessary to order clamp separately on early released packages. PARTS LIST FUEL PRESSURE REGULATOR PACKAGE FOR 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO.4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 PARTS LIST 78 AMP ALTERNATOR PACKAGE FOR 1981-1985 B MODEL TRUCKS WITH 5.2L OR 5.9L ENGINES PACKAGE PART NO. 4397615 QTY. PART NAME PART NO. 1 78 AMP Alternator Assembly - Complete 4111204 1 Alternator Overlay Wiring Harness 4362343 4 Tie Wrap 6015756 1 Gasket - Bulkhead Connector 4055399 FIGURE 4B - Mounting Fuel Resevoir/Filter 1. Fuel Filter/ Reservoir - 4418012 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 149 2. Screw - Self Tapping - 6022777 (2 Req.) 3. Tube Assy - Fuel Pump to Reservoir - 4306968 4. Return Hose & Sleeve Assy - 4418006 5. Hose Clamps - 6500650 (2 Req.) - 1/4" 6. Hose-Fuel Pump Outlet to Reservoir Inlet - 4203576 7. Hose-Reservoir Outlet to Carburetor or Regulator Fuel Tube - 4203576 8. Hose Clamps - 6500651 (4 Req.) - 5/16" Included but not shown: 2 piece Convolute Tubing - 4279993 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1 SCREW & WASHER - 6022254 2 REGULATOR BRACKET - 4418010 3 REGULATOR - 4418OD9 4 TUBE - REGULATOR TO CARB - 4418008 5 TUBE - RESERVOIR HOSE TO REGULATOR - 4418014 6 SCREW (2 EA.) - REGULATOR TO BRACKET - 6033066 7 CLAMP (5116) - 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 182985 > Jun > 85 > ECM Warm Surge At Steady Speed Powertrain Control Module: All Technical Service Bulletins ECM - Warm Surge At Steady Speed Models 1985 Trucks Equipped With 5.2L-2BBL Engine, O2 Feedback Carburetor System & Automatic Transmission With California Emissions Package Subject Warm Surge at Steady Speed Index DRIVEABILITY Date June 24, 1985 No.. 18-29-85 SYMPTOM/CONDITION Vehicle will exhibit a surge at steady speeds with engine at full operating temperature. PARTS REQUIRED Driveability Package PN 4397618 Contains: 1 Vacuum Delay Valve PN 4173433 1 Hose Routing Label PN 4179843 Must be ordered separately: 1 ESA Module PN 4289977 1 CVSCC PN 4095231 1 Authorized Modification Label PN 4275086 REPAIR PROCEDURE 1. Remove existing ESA module (PN 4289637) and install supplied ESA module, PN 4289977. 2. Drain coolant and remove existing CVSCC (coolant vacuum switch cold closed) and install supplied CVSCC, PN 4095231. 3. Cut one 1-1/2" section of 3/16" vacuum hose, PN 4105167 (serviced in 50 foot rolls). 4. Install the 1-1/2" section of 3/16" hose on the natural colored end of the vacuum delay valve, PN 4173433, supplied in package. 5. The EGR solenoid is mounted on the fender shield (right side of engine compartment). It can be identified by a "white" right angle vacuum connector. Remove the white right angle vacuum connector on the EGR solenoid and install the delay valve assembly on the EGR solenoid. The 1-1/2" piece of 3/16" hose is attached in place of the removed white right angle connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 182985 > Jun > 85 > ECM Warm Surge At Steady Speed > Page 154 FIGURE 1 - Vacuum Delay Valve - Attachment Procedure The white right angle connector is then attached to the orange colored side of the vacuum delay valve (Figure 1). 6. Wipe existing hose routing label clean. Install hose routing label, PN 4179843, supplied in package over the original label. FIGURE 2 7. Type Authorized Modification Label, PN 4275086, as shown in Figure 2 and install next to the VECI label. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 08-15-61-90 Trucks 0.5 Hrs. Vans 0.6 Hrs. FAILURE CODE: AM - Authorized Modification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations Powertrain Control Module: Component Locations Electronic Ignition System Components On Firewall Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 157 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 160 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > Emissions Maintenance Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Emissions Maintenance Lamp Relay: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > Emissions Maintenance Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 166 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Power Module <--> [Electronic Spark Control Module] > Component Information > Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Power Module <--> [Electronic Spark Control Module] > Component Information > Locations > Page 171 Power Module: Description and Operation The spark control computer controls the air fuel ratio of the carburetor and the ignition timing. The computer receives signals from various sensors and processes them to determine the air fuel ratio of the carburetor and ignition timing. There are as many as six types of sensors which can be used to supply the spark control computer with the necessary information needed to fire the spark plugs at the precise moment and, with the feedback carburetor, change the air-fuel ratio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Specifications > Electrical Specifications Ignition Control Module: Electrical Specifications Part No. Spark Advance Test Electronic EGR Time Delay Electronic Throttle Control 4289601 38 +/- 4 deg at 2000 rpm 60 min 90 sec Note: After start or 2 sec. after throttle close condition. 4289603 33 +/- 4 deg at 2000 rpm 45 min 60 sec Note: After start or 1 sec. after throttle close condition. 4289613 30 +/- 4 deg at 2000 rpm 60 min 90 sec Note: After start or 1 sec. after throttle close condition. 4289615 30 +/- 4 deg at 2000 rpm 28 min 60 sec Note: After start or 2 sec. after throttle close condition. 4289617 30 +/- 4 deg at 2000 rpm 65 min 60 sec 4289621 37 +/- 4 deg at 2000 rpm 60 min --4289637 34 +/- 4 deg at 2000 rpm 25 min 25 sec Note: After start or 1 sec. after throttle close position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Specifications > Electrical Specifications > Page 176 Ignition Control Module: Mechanical Specifications Part No. Spark Advance Test Electronic EGR Time Delay Electronic Throttle Control 4289601 38 +/- 4 deg at 2000 rpm 60 min 90 sec Note: After start or 2 sec. after throttle close condition. 4289603 33 +/- 4 deg at 2000 rpm 45 min 60 sec Note: After start or 1 sec. after throttle close condition. 4289613 30 +/- 4 deg at 2000 rpm 60 min 90 sec Note: After start or 1 sec. after throttle close condition. 4289615 30 +/- 4 deg at 2000 rpm 28 min 60 sec Note: After start or 2 sec. after throttle close condition. 4289617 30 +/- 4 deg at 2000 rpm 65 min 60 sec 4289621 37 +/- 4 deg at 2000 rpm 60 min --4289637 34 +/- 4 deg at 2000 rpm 25 min 25 sec Note: After start or 1 sec. after throttle close position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 179 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Spark Control Relay > Component Information > Locations Spark Control Relay: Locations Electronic Ignition System Components On Firewall Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection Starter Relay: Testing and Inspection 1. Place transmission in Neutral and apply parking brake. 2. Check for battery voltage between starter relay battery terminal and ground. 3. Connect jumper wire on starter relay between battery and ignition terminals. 4. If engine does not crank, connect a second jumper wire to starter relay between ground terminal and good ground and repeat test. 5. If engine cranks in step 4, transmission linkage is misadjusted or neutral safety switch is defective. 6. If engine does not crank in step 4, starter relay is defective. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Power Window Relay: Locations Door Lock And Power Window Circuit Breaker And Relays Location The relay is located behind the dash panel, to the left of the glove box. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 191 Power Window Relay: Testing and Inspection Locate the window lift relay and test as follows: 1. Check for a constant power source at the LG wire. ^ If power is present, go to step 2. ^ If power is not present, check the circuit breaker and connecting wires. 2. Check for ground at the WT wire. ^ If a ground is present, go to step 3. ^ If a good ground is not present, check for an open in the WT wire to ground. 3. Check for a power source at the DB wire when the key is turned to the "run" position. ^ If power is present, go to step 4. ^ If power is not present, check for an open in the DB wire from the ignition switch or a defective ignition feed fuse. 4. Check for power at the TN wire. ^ If power is present, the relay is operating properly. ^ If power is not present, replace the relay. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 192 Power Window Relay: Service and Repair Door Lock And Power Window Circuit Breaker And Relays Location Disconnect the battery negative terminal. Remove the wire connector from the relay. Remove the attaching bolt that holds the relay to the instrument panel. Install by attaching relay to the instrument panel and connecting the wires to the relay. Connect the battery negative terminal and test the system for proper operation. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Switch <--> [Power Door Lock Switch] > Component Information > Locations Door Lock Switch: Locations Power Door Lock Equipment The door switch is located inside each of the front doors, just above the access opening. It is riveted to the inner door panel and has connecting rods to the lock knob and the door latch. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Switch <--> [Power Door Lock Switch] > Component Information > Locations > Page 198 Door Lock Switch: Testing and Inspection NOTE: The door switches are available only on the front doors. Remove the door trim to gain access to the door switch. Power Door Lock Equipment Unplug the door switch connector and connect an ohmmeter between the center terminal and one of the outer terminals of the door switch. Move the lock knob between the lock and unlock positions several times. The ohmmeter should show continuity (zero resistance) in only one of the positions. Connect the ohmmeter between the center terminal and the other outer terminal and repeat the lock knob movement. The ohmmeter should now show continuity Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Switch <--> [Power Door Lock Switch] > Component Information > Locations > Page 199 (zero resistance) in the other lock knob position. If the door switch does not test properly, it is defective. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Switch <--> [Power Door Lock Switch] > Component Information > Locations > Page 200 Door Lock Switch: Service and Repair Remove the battery negative cable. Remove door trim and panel(s) Power Door Lock Equipment Disconnect wire plug from door switch. Disconnect lock knob rod retaining clip and remove lock knob rod from door switch. Disconnect retaining clip on link between latch assembly and door switch. Center punch door switch mounting rivet and drill out rivet head. Install new door switch using either a new rivet or a matching nut, bolt, and washer assembly. Install link between latch assembly and door switch. Install lock knob rod to door switch. Connect wire plug to door switch. Install battery negative cable and test power door lock system. Install door trim panel(s). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions Brake Fluid Pressure Sensor/Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 206 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 207 Brake Fluid Pressure Sensor/Switch: Electrical Diagrams Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 208 Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 209 Fig. 20 Ignition Switch With Tilt Wheel Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Page 210 Brake Fluid Pressure Sensor/Switch: Testing and Inspection Brake Warning Switch Testing 1. Raise the car on a hoist and open a wheel cylinder bleeder while a helper depresses the brake pedal and observes the warning light. 2. If the light fails to light, inspect for a burned out bulb, disconnected socket, or a broken or disconnected wire at the switch. 3. If the bulb is not burned out and the wire continuity is uninterrupted, check the service brake warning switch operation with a test lamp between the switch terminal and a voltage source. 4. If light still fails to light, disconnect the brake tubes from the valve assembly and install a new valve assembly. 5. If a new valve is installed, bleed the system. CAUTIONS: - Do not disassemble valve to reset the piston. - The warning switch is not serviced separately. Do not remove the switch or attempt to repair. NOTE: After repairing and bleeding the brake system, applying the brakes with moderate force will hydraulically recenter the piston and automatically turn off the warning light. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Parking Brake Warning Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 215 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 216 Parking Brake Warning Switch: Electrical Diagrams Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 217 Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Testing and Inspection Coolant Level Sensor: Testing and Inspection Recreational Vehicle (Coolant Level) Sensor Package Fig. 3 Recreational vehicle sensor package instrument cluster. 1980 Fig. 4 Recreational vehicle sensor package instrument cluster. 1981-82 The recreational vehicle sensor package consists of a separate instrument cluster which allows the driver to monitor the following conditions: engine oil level, engine coolant level, transmission fluid level and transmission fluid temperature. TROUBLESHOOTING VOLTAGE LIMITER TEST 1. Connect voltmeter between temperature sending unit (locating in fitting in bottom radiator tank) and a suitable ground. Do not disconnect electrical connector from sending unit. 2. Turn ignition switch to On position and observe voltmeter. 3. If voltmeter needle fluctuates, the voltage limiter is operating properly. 4. If voltmeter does not fluctuate, replace voltage limiter. The voltage limiter is located on the sensor panel. To gain access to the limiter, remove panel and unsnap the back cover. TEMPERATURE GAUGE TEST 1. Disconnect electrical connector from temperature sending unit in lower radiator tank. 2. Connect tester No. C-3826 or equivalent between temperature sending unit and a suitable ground. 3. Move tester pointer to "C" position, then turn ignition switch On and observe temperature gauge. Temperature gauge should read within 1/8 inch of "C". 4. Move tester pointer to "M" position. Temperature gauge should now advance to normal range left of 1/2 position on dial. 5. Move tester pointer to "H" position. Temperature gauge should now advance to "H" position on dial. 6. If temperature gauge responds to tests described in steps 3, 4 and 5, but does not operate when sending unit electrical connector is attached, the sending unit is defective and should be replaced. 7. If temperature gauge does not respond to tests described in steps 3, 4 and 5, check for loose connections, broken wire, open printed circuit or faulty gauge. OIL LEVEL PUSH BUTTON SWITCH 1. Inspect switch for poor solder connections and repair or replace as necessary. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Testing and Inspection > Page 222 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the switch should be replaced. To replace switch, remove circuit board and push switch toward back of sensor housing. PRINTED CIRCUIT BOARD 1. Inspect conductors for cracks or damaged circuits. 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the sensor panel assembly should be replaced. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 228 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations Coolant Temperature Sensor/Switch (For Computer): Component Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 231 Coolant Temperature Sensor/Switch (For Computer): Connector Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 232 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Coolant Temperature Switch Coolant Temperature Sensor/Switch (For Computer): Description and Operation Coolant Temperature Switch Fig. 4 Switches & sensors location. V8 engine On V8 engines the coolant switch is located on the front of the intake manifold, Fig. 4. It operates by supplying a signal to the computer when the engine coolant temperature is below 150~ F. This information is required to prevent a change in air fuel ratio until engine operation temperature is reached except there is no control of canister purging. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Coolant Temperature Switch > Page 235 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Description The coolant temperature sensor measures temperature of the engine coolant. The coolant temperature sensor is mounted in the thermostat housing or in water passage of intake manifold. The sensor monitors engine coolant (operating) temperature. It supplies the logic module with a voltage signal which varies with coolant temperature. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations Temperature Sensor (Gauge): Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Diagram Information and Instructions Brake Switch (Cruise Control): Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Diagram Information and Instructions > Page 244 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Diagram Information and Instructions > Page 245 Brake Switch (Cruise Control): Electrical Diagrams Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 1 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Diagram Information and Instructions > Page 246 Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 2 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Diagram Information and Instructions > Page 247 Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 3 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 248 Brake Switch (Cruise Control): Testing and Inspection Refer to Speed Control Wiring Diagrams. Prior to performing any tests, ensure servo or valve body and electronic module are properly tested. Fig. 2 Speed control wiring diagram. 1980-84 Vans, Wagons & Front Sections Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 249 Fig. 3 Speed control wiring diagram. 1981-84 Ramcharger, Trail Duster & Conventional Cabs Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 250 Fig. 4 Speed control wiring diagram. 1982-84 Rampage & 1983 Scamp Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 251 Fig. 5 Speed control wiring diagram. 1984 Mini-Vans/Wagons (1985 similar) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 252 Fig. 6 Speed control wiring diagram. 1985 Conventional Cabs & Ramcharger Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 253 Fig. 7 Speed control wiring diagram. 1985 rear wheel drive Ram Van & Wagons Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 254 Fig. 8 Speed control wiring diagram. 1986-87 Conventional Cabs & Ramchargers Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 255 Fig. 9 Speed control wiring diagram. 1986 rear wheel drive Ram Van & Wagons Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 256 Fig. 10 Speed control wiring diagram. 1986 Mini-Vans/Wagons Exc. 1986-87 Mini-Vans/Wagons 1. Disconnect double connector at switch pigtail, then connect a suitable 12 volt power source to either terminal. 2. Connect a suitable test lamp to other terminal and ground. Test lamp should illuminate when brake pedal is in normal position and go off when brake pedal is depressed 1/2 - 3/8 inch maximum. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations Clutch Switch: Locations On Clutch Pedal Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 260 Clutch Switch: Testing and Inspection Clutch Switch Test (Manual Transmission Only) Refer to Speed Control Wiring Diagrams. Prior to performing any tests, ensure servo or valve body and electronic module are properly tested. Fig. 2 Speed control wiring diagram. 1980-84 Vans, Wagons & Front Sections Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 261 Fig. 3 Speed control wiring diagram. 1981-84 Ramcharger, Trail Duster & Conventional Cabs Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 262 Fig. 4 Speed control wiring diagram. 1982-84 Rampage & 1983 Scamp Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 263 Fig. 5 Speed control wiring diagram. 1984 Mini-Vans/Wagons (1985 similar) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 264 Fig. 6 Speed control wiring diagram. 1985 Conventional Cabs & Ramcharger Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 265 Fig. 7 Speed control wiring diagram. 1985 rear wheel drive Ram Van & Wagons Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 266 Fig. 8 Speed control wiring diagram. 1986-87 Conventional Cabs & Ramchargers Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 267 Fig. 9 Speed control wiring diagram. 1986 rear wheel drive Ram Van & Wagons Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 268 Fig. 10 Speed control wiring diagram. 1986 Mini-Vans/Wagons Exc. 1986-87 Mini-Vans/Wagons 1. Disconnect double connector at switch pigtail, then connect a 12 volt power source to either end of switch terminal. 2. Connect a suitable test light to remaining terminal end and ground. 3. Test light should be "on" when pedal is in normal position and "off" when pedal is depressed. 4. If above step is not as specified, replace clutch switch. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection Speed Control Switch: Testing and Inspection Refer to Speed Control Wiring Diagrams. Prior to performing any tests, ensure servo or valve body and electronic module are properly tested. Fig. 2 Speed control wiring diagram. 1980-84 Vans, Wagons & Front Sections Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 272 Fig. 3 Speed control wiring diagram. 1981-84 Ramcharger, Trail Duster & Conventional Cabs Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 273 Fig. 4 Speed control wiring diagram. 1982-84 Rampage & 1983 Scamp Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 274 Fig. 5 Speed control wiring diagram. 1984 Mini-Vans/Wagons (1985 similar) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 275 Fig. 6 Speed control wiring diagram. 1985 Conventional Cabs & Ramcharger Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 276 Fig. 7 Speed control wiring diagram. 1985 rear wheel drive Ram Van & Wagons Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 277 Fig. 8 Speed control wiring diagram. 1986-87 Conventional Cabs & Ramchargers Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 278 Fig. 9 Speed control wiring diagram. 1986 rear wheel drive Ram Van & Wagons Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 279 Fig. 10 Speed control wiring diagram. 1986 Mini-Vans/Wagons Rear Wheel Drive Models 1. Check fuse for continuity. 2. Disconnect four wire electrical connector at steering column. 3. Connect a suitable 12 volt power source to black wire terminal of switch harness connector. 4. Attach one lead of a suitable test lamp to ground, then attach the second lead to yellow wire terminal. Test lamp should illuminate with speed control switch in "on" position. Test lamp should be off when set button is depressed, or when speed control switch is in "off" position. 5. Attach test lamp lead to dark blue wire. Test lamp should illuminate with slide switch in "on" position and be off with slide switch in "off" position. 6. Attach test lead to white wire. Test lamp should be off with slide switch in "on" position, illuminate when set button is depressed, and be off when switch is released. Test lamp should illuminate when slide switch is moved to "Resume" position, and go off when slide switch is released. 7. Replace speed control switch if test lamp does not respond as indicated. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 280 Front Wheel Drive Models, Exc. 1986-87 Mini-Vans/Wagons 1. Check fuse for continuity. 2. Disconnect four wire electrical connector at steering column. 3. Connect a suitable 12 volt power source to yellow wire terminal of switch harness connector. 4. Attach one lead of a suitable test lamp to ground, then the second lead to brown wire with red tracer terminal test lamp should illuminate with speed control switch in "on" position. Test lamp should be off when set button is depressed, or when speed control switch is in "off" position. 5. Attach test lamp lead to dark blue wire with white tracer. Test lamp should illuminate with slide switch in "on" position, and be off with slide switch in "off" position. 6. Attach test lead to white wire with red tracer. Test lamp should be off with slide switch in "on" position, illuminate when set button is depressed, and be off when switch is released. Test lamp should illuminate when slide switch is moved to "Resume" position, then go off when slide switch is released. 7. Replace speed control switch if test lamp does not respond as indicated. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 281 Speed Control Switch: Service and Repair Fig. 22 Removing wire terminals REAR WHEEL DRIVE MODELS 1. Disconnect battery ground cable. 2. Disconnect speed control connector at lower end of column. 3. Remove steering wheel. 4. Remove turn signal switch, then the lever attaching screws. 5. Remove steering column cover plate to gain access to lead wires at lower end of switch, then remove wires and terminals from connector using tool No. C-4135 or equivalent. 6. Tape terminals, then remove lever and wires. 7. Reverse procedure to install. A guide wire will be required to install wiring harness of new speed control switch through steering column opening. On tilt or telescopic steering columns, insert guide wire through turn signal lever opening in column. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Engine Mounted Switches & Sensors. Top Of Engine Applicable to: V8 Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 291 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 292 Fig. 8 Cargo, Dome & Map Lamps Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 301 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 302 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 303 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 304 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 305 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 306 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 307 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 308 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 309 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 310 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 311 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 312 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 313 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 314 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 315 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock Technical Service Bulletin # 181985A Date: 851201 Fuel System - Vapor Lock Models 1981-1985 Van & Wagon Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 20, 1985 No. 18-19-85 REVISION A P-4782-C This bulletin supersedes Technical Service Bulletin #18-19-85 which should be removed from your files. The model application has been expanded to include 1981 and 1982 model years. SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING TWO PART NUMBERS: Vapor Lock Package With 22 Gallon Fuel Tank PN 4397611 Vapor Lock Package With 36 Gallon Fuel Tank PN 4397612 ADDITIONAL PARTS INFORMATION ON NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 All vehicles equipped with dual air conditioning, without electrically heated rear window defroster, and with 60 amp alternator must order the following package in addition to the vapor lock package. If vehicle is equipped with a 114 amp alternator, do not order this package or make any changes to the charging system. 1 78 AMP Alternator Package PN 4397615 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 320 Refer to parts list for contents of each package. Must be ordered separately: 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. REPAIR PROCEDURE A.Engine Compartment Harness Pn 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1A - ENGINE COMPARTMENT WIRING 3. Remove engine cover. Install the bare eyelet terminal of overlay harness, PN 4362295, to the negative terminal of the ignition coil as shown in Figure 1-A. FIGURE 1B - ENGINE COMPARTMENT WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 321 4. Route and secure the engine overlay harness, PN 4362295, along the existing main engine wiring harness using the existing wiring clips and two tie wraps, PN 6015756 (Figure 1-B). FIGURE 1C - ENGINE COMPARTMENT WIRING 5. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness to the bulkhead connector using the existing wiring clips and three tie wraps, PN 6015756 (Figure 1-C). Loop and tape any excess wire of the engine overlay harness. FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 6. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar multi-purpose grease PN 4318063, and snap into cavity #14 of the engine side of the bulkhead connector (Figure 1-D). B.Instrument Panel Harnesses Pn 4362289, All Models Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 322 FIGURE 2A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) 1. Remove instrument panel left lower trim panel. 2. Insert two bare terminals from instrument panel overlay harness, PN 4362289, into the instrument panel side of the bulkhead connector (Figure 2-A). a. Gray with black tracer wire into cavity #14. b. Dark green wire into cavity #13. INSTRUMENT PANEL WIRING 3. Secure bare eyelet ground terminal (white with black tracer wire) from instrument panel overlay harness, PN 4362289, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). NOTE: CERTAIN VEHICLES ARE ALREADY EQUIPPED WITH THE GROUND SCREW. IF SO, DISCARD THE SUPPLIED SCREW. FIGURE 2C - INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 323 FIGURE 2D - INSTRUMENT PANEL WIRING 4. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-C). Install the extracted terminal (orange wire) into the natural colored 1-way connector supplied with instrument panel overlay harness, PN 4362289. Install the bare terminal (orange wire) from the instrument panel overlay harness, PN 4362289, into the vacated cavity in the ignition switch connector. Reconnect the natural colored 1-way connectors supplied with the instrument panel overlay harness, PN 4362289, and reconnect the ignition switch connectors (Figure 2-C and 2-D). FIGURE 2E - TYPICAL CONTROL MODULE MOUNTING 5. Connect the control (auto shut-down) module, PN 5226640, to the natural colored 8-way connector from instrument panel overlay harness, PN 4362289. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 324 FIGURE 2D - INSTRUMENT PANEL WIRING FIGURE 2F - INSTRUMENT PANEL WIRING 6. Route the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289, to the back of the brake bracket for mating in a later step (Figures 2-B, 2-D, and 2-F). Secure instrument panel overlay harness, PN 4362289, using tie wrap, PN 6015756, to keep it clear of any possible interferences. Only one of the following installation procedures (Step 7) will be used. Take notice of which one applies to the vehicle being repaired. 7. Without Auxiliary Air Conditioning and/or Heater - Jumper Harness PN 4362291 a. Remove instrument panel hood and bezel assembly and remove radio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 325 FIGURE 2D - INSTRUMENT PANEL WIRING b. Route instrument panel jumper harness, PN 4362291, from the back of the brake bracket to the existing 3-way red molded connector. Secure by using existing wiring clips (Figure 2-D). c. Insert the bare bullet terminal (black with white tracer wire) from instrument panel jumper harness, PN 4362291, into the existing 3-way red molded connector from the main instrument panel wiring harness (Figure 2-D). d. Mate the orange colored 1-way connector from instrument panel jumper harness, PN 4362291, to the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). e. Reinstall instrument panel hood and bezel assembly and install radio. FIGURE 2F - INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater and Power Windows - Jumper Harness PN 4362292 a. Disconnect from each other, the two existing brown colored 1-way connectors located near the left instrument panel vent (Figure 2-F). Reconnect these two brown colored 1-way connectors to the two brown colored 1-way connectors from instrument panel jumper harness, PN 4362292 (Figure 2-F). b. Mate the orange colored 1-way connector from the instrument panel jumper harness, PN 4362292, to the orange colored 1-way connector from instrument panel overlay harness, PN 4362289 (Figure 2-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 326 INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater Without Power Windows - Relay Harness PN 4362290 a. Remove instrument panel hood and bezel assembly. Remove radio. b. Install the ignition switch protection relay, PN 4162597, to the back of the brake bracket (mounting location shown in Figure 2-B) and attach instrument panel relay harness, PN 4362290, to relay. c. Secure bare eyelet ground terminal (white wire) from instrument panel relay harness, PN 4362290, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING d. Route the dark blue wire from the instrument panel relay harness, PN 4362290 to the existing 3-way red molded connector using existing wiring clips. Insert bullet terminal (dark blue wire) into red molded connector (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 327 INSTRUMENT PANEL WIRING e. Insert bare bullet terminal (red wire) from instrument panel relay harness, PN 4362290, into the existing 3-way yellow molded connector from the main instrument panel wiring harness (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING f. Mate the orange colored 1-way connector from instrument panel relay harness, PN 4362290, to the colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). g. Install the instrument panel left lower trim panel, instrument panel hood, bezel assembly and radio. C.In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Feed red and yellow molds of body wiring harness, PN 4362293, through slot in the crossmember. Remove existing screw for gauge unit ground. Install eyelet terminal of harness, PN 4362293 (and ground eyelet terminal of 36 gallon tank gauge/pump unit) and torque ground screw to 36 inch pounds. CAUTION: GROUND SCREW MUST BE TIGHTENED SECURELY TO OPERATE ELECTRIC PUMP AND GAUGE UNIT. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 328 FIGURE 3A - BODY WIRING FIGURE 3B - BODY WIRING Install red mold of body harness, PN 4362293, onto red stud of gauge/pump unit. Install yellow mold of harness, PN 4362293, onto black stud of gauge/pump unit (figure 3-a or 3-b). Install molded blade terminal of harness, PN 4362293, onto blade terminal of 22 gallon gauge unit only. NOTE: PREVIOUS GAUGE UNIT GROUND WILL NOT BE USED ON 22 GALLON GAUGE/PUMP UNIT. ON 36 GALLON GAUGE PUMP UNIT, THE GROUND WIRE ON HARNESS PN 4362293 WILL NOT BE USED. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. Set aside the rest of harness, PN 4362293, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. D.Body Wiring Harness Pn 4362293 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 329 FIGURE 3C - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 330 FIGURE 3-F - BODY WIRING 1. Vehicles With 36 Gallon Tank Route harness, PN 4362293, to the right (passenger) side of vehicle along the fuel line tubes and tie wrap (1). At right frame rail, route harness forward to next crossmember (Figures 3-C and 3-E). Tie wrap harness in three (3) places. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 331 FIGURE 3D - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 332 FIGURE 3-F - BODY WIRING Vehicles With 22 Gallon Tank Route harness, PN 4362293, along right frame rail following brake lines (Figures 3-D and 3-E). Tie wrap in two (2) places. NOTE: HARNESS MUST BE ABOVE SHOCK STRUT WITH EITHER 36 OR 22 GALLON TANK. 2. At crossmember, route harness to the left rail following existing brake lines and tie wrap in two (2) places. At left rail, route harness forward through access holes following existing brake lines. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 333 FIGURE 3-F - BODY WIRING NOTE: HARNESS SHOULD BE TIGHT IN THIS AREA THE WRAP IN FOUR (4) PLACES (FIGURE 3-E). 3. At engine compartment, route harness through existing speedometer cable clips to bulkhead connector. If excess wiring exists; loop, tie wrap (2), and install into existing clip (Figure 3-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 334 FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 4. Plug bare terminal of harness, PN 4362293, into cavity #13 of the bulkhead connector (Figure 1-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 335 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 336 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 337 FIGURE 9 - ELECTRIC FUEL PUMP WIRING DIAGRAMW/AUX A/C & HEATER-W/O POWER WINDOWS 5. For all vehicles except those which require a 78 amp alternator package: Reinstall instrument panel side, then engine compartment side of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURES 7, 8, OR 9 FOR OVERALL WIRING DIAGRAMS. E.Engine Compartment Fuel Reservoir/Filter Lnstallation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 338 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER 1. Using template, PN 4418011, mark and drill (from engine side of passenger side chassis rail) two (2) holes .290" diameter (L size drill) as shown in Figure 4-A. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 339 FIGURE 4B - Mounting Fuel Resevoir/Filter 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. NOTE: RUBBER SPLASH SHIELD MAY HAVE TO BE CUT OUT AROUND FUEL RESERVOIR. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube, PN 4306968 (Figure 4-B). 4. Install return hose assembly, PN 4418006, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end (Figure 4-B). 5. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 42O3576. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 340 FIGURE 4B - Mounting Fuel Resevoir/Filter 6. Install one 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the fuel pump outlet tube to the reservoir/filter inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). 7. Install the other 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 8. Tighten all hose clamps to 10 inch pounds. FIGURE 10 9. Type Authorized Modification Label, PN 4275086, as shown in Figure 10 and attach near VECI label. 10. For all models except 1981-1984 equipped with Carter Thermoquad 4BBL carburetor or dual air conditioning units without electrically Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 341 heated rear window defroster. Reconnect battery. Start the engine, and inspect the entire system for fuel leaks and proper wire and hose routing. 11. Reinstall engine cover. F.1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (Pn 4397 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6O22254, (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT, AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6O22254. THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 342 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference with nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose-to-regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. For all models except those equipped with dual air conditioning units, without electrically heated rear window defroster and with 60 amp alternator: 6. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 7. Reinstall engine cover. G.Vehicles Equipped With Dual Air Conditioning Units, Without Electrically Heated Rear Defroster, and With 60 Amp Alternator. I Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 343 HEADLAMP AND DASH WIRING ASSEMBLY 1. Disconnect the battery positive lead (single in-line connection) from the headlamp and dash wiring assembly (Figure 6-A). FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 2. Remove the following wires from the engine compartment side of the bulkhead connector (Figure 6-B). a. Red wire from cavity #39 (ammeter). b. Black wire from cavity #33 (ammeter). Cut off the terminals and wrap tape around each end of both wires to insure that shorting cannot occur. Then tape the wrapped wires back against the main harness. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 344 FIGURE 6-C - 78 AMP ALTERNATOR WIRING 3. Remove the alternator output wire (heavy gauge) from the 60 amp alternator (Figure 6-C). Cut the wire off leaving approximately three (3) inches of wire extending out of the main harness. Tape the end of the lead thoroughly. Then fold and tape the lead back against the main harness to prevent shorting. 4. Remove 60 amp alternator assembly and install 78 amp alternator assembly, PN 4111204, per the service manual alternator replacement procedure. HEADLAMP AND DASH WIRING ASSEMBLY Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 345 FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 5. Beginning at the bulkhead, route and connect the wiring assembly, PN 4362343, as shown in Figure 6-A. Use the existing clip for main harness and tie wrap with three (3) tie wraps, PN 6015756. Insert the two bare terminals from alternator overlay wiring harness, PN 4362343, as shown in Figure 6-B as follows: NOTE: THE 4362343 ALTERNATOR OVERLAY HARNESS WAS MANUFACTURED WITH THE RED AND BLACK WIRES REVERSED. THEREFORE, IT WILL BE NECESSARY TO INSTALL THE BLACK WIRE (LABELED RED) INTO CAVITY #39 (RED WIRE PREVIOUSLY REMOVED), AND THE RED WIRE (LABELED BLACK) INTO CAVITY #33 (BLACK WIRE PREVIOUSLY REMOVED). FAILURE TO REVERSE THESE TWO WIRES WILL RESULT IN THE AMMETER SHOWING THE OPPOSITE CHARGE INDICATION. a. Red wire into cavity #33 (ammeter) - (labeled as black wire). b. Black wire into cavity #39 (ammeter) - (labeled as red wire). 6. Install wiring assembly, PN 4362343, alternator output terminal to new 78 amp alternator. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 346 FIGURE 6A1 7. Connect the battery positive lead and the headlamp and dash wiring assembly lead to those of the alternator overlay wiring assembly, PN 4362343, as shown in circled view of Figure 6-A. 8. Reinstall instrument panel half, then engine compartment half of bulkhead connector and torque to 40 inch pounds. 9. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 10. Reinstall engine cover. POLICY: Reimbursable within the provisions of the warranty and repair manual. TIME ALLOWANCE: Labor Operation No. 14-70-17-94 - All 2.5 Hrs. Optional Equipment: 14-70-17-60 - Carter Thermoquad Carburetor 0.5 Hrs. 14-70-17-61 - With Auxiliary A/C - Without Elec. 0.7 Hrs. Rear Window Defroster 14-70-17-62 - Without Auxiliary A/C 0.3 Hrs. 14-70-17-63 - With Auxiliary A/C - Without 0.4 Hrs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 347 Power Windows FAILURE CODE: AM - Authorized Modification Part List VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 22 GALLON FUEL TANK PACKAGE PART NO. 4397611 QTY PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075432 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Seal - Fuel Tank Gauge 3404451 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 36 GALLON FUEL TANK PACKAGE PART NO. 4397612 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075436 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Gasket - Fuel Tank Sending Unit 4115209 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 348 *It may be necessary to order clamp separately on early released packages. PARTS LIST FUEL PRESSURE REGULATOR PACKAGE FOR 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO.4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 PARTS LIST 78 AMP ALTERNATOR PACKAGE FOR 1981-1985 B MODEL TRUCKS WITH 5.2L OR 5.9L ENGINES PACKAGE PART NO. 4397615 QTY. PART NAME PART NO. 1 78 AMP Alternator Assembly - Complete 4111204 1 Alternator Overlay Wiring Harness 4362343 4 Tie Wrap 6015756 1 Gasket - Bulkhead Connector 4055399 FIGURE 4B - Mounting Fuel Resevoir/Filter 1. Fuel Filter/ Reservoir - 4418012 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 349 2. Screw - Self Tapping - 6022777 (2 Req.) 3. Tube Assy - Fuel Pump to Reservoir - 4306968 4. Return Hose & Sleeve Assy - 4418006 5. Hose Clamps - 6500650 (2 Req.) - 1/4" 6. Hose-Fuel Pump Outlet to Reservoir Inlet - 4203576 7. Hose-Reservoir Outlet to Carburetor or Regulator Fuel Tube - 4203576 8. Hose Clamps - 6500651 (4 Req.) - 5/16" Included but not shown: 2 piece Convolute Tubing - 4279993 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1 SCREW & WASHER - 6022254 2 REGULATOR BRACKET - 4418010 3 REGULATOR - 4418OD9 4 TUBE - REGULATOR TO CARB - 4418008 5 TUBE - RESERVOIR HOSE TO REGULATOR - 4418014 6 SCREW (2 EA.) - REGULATOR TO BRACKET - 6033066 7 CLAMP (5116) - 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 355 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 356 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 357 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 358 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 359 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 360 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 361 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 362 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 363 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 364 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 365 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 366 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 367 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 368 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 369 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock Technical Service Bulletin # 181985A Date: 851201 Fuel System - Vapor Lock Models 1981-1985 Van & Wagon Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 20, 1985 No. 18-19-85 REVISION A P-4782-C This bulletin supersedes Technical Service Bulletin #18-19-85 which should be removed from your files. The model application has been expanded to include 1981 and 1982 model years. SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING TWO PART NUMBERS: Vapor Lock Package With 22 Gallon Fuel Tank PN 4397611 Vapor Lock Package With 36 Gallon Fuel Tank PN 4397612 ADDITIONAL PARTS INFORMATION ON NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 All vehicles equipped with dual air conditioning, without electrically heated rear window defroster, and with 60 amp alternator must order the following package in addition to the vapor lock package. If vehicle is equipped with a 114 amp alternator, do not order this package or make any changes to the charging system. 1 78 AMP Alternator Package PN 4397615 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 374 Refer to parts list for contents of each package. Must be ordered separately: 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. REPAIR PROCEDURE A.Engine Compartment Harness Pn 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1A - ENGINE COMPARTMENT WIRING 3. Remove engine cover. Install the bare eyelet terminal of overlay harness, PN 4362295, to the negative terminal of the ignition coil as shown in Figure 1-A. FIGURE 1B - ENGINE COMPARTMENT WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 375 4. Route and secure the engine overlay harness, PN 4362295, along the existing main engine wiring harness using the existing wiring clips and two tie wraps, PN 6015756 (Figure 1-B). FIGURE 1C - ENGINE COMPARTMENT WIRING 5. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness to the bulkhead connector using the existing wiring clips and three tie wraps, PN 6015756 (Figure 1-C). Loop and tape any excess wire of the engine overlay harness. FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 6. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar multi-purpose grease PN 4318063, and snap into cavity #14 of the engine side of the bulkhead connector (Figure 1-D). B.Instrument Panel Harnesses Pn 4362289, All Models Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 376 FIGURE 2A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) 1. Remove instrument panel left lower trim panel. 2. Insert two bare terminals from instrument panel overlay harness, PN 4362289, into the instrument panel side of the bulkhead connector (Figure 2-A). a. Gray with black tracer wire into cavity #14. b. Dark green wire into cavity #13. INSTRUMENT PANEL WIRING 3. Secure bare eyelet ground terminal (white with black tracer wire) from instrument panel overlay harness, PN 4362289, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). NOTE: CERTAIN VEHICLES ARE ALREADY EQUIPPED WITH THE GROUND SCREW. IF SO, DISCARD THE SUPPLIED SCREW. FIGURE 2C - INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 377 FIGURE 2D - INSTRUMENT PANEL WIRING 4. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-C). Install the extracted terminal (orange wire) into the natural colored 1-way connector supplied with instrument panel overlay harness, PN 4362289. Install the bare terminal (orange wire) from the instrument panel overlay harness, PN 4362289, into the vacated cavity in the ignition switch connector. Reconnect the natural colored 1-way connectors supplied with the instrument panel overlay harness, PN 4362289, and reconnect the ignition switch connectors (Figure 2-C and 2-D). FIGURE 2E - TYPICAL CONTROL MODULE MOUNTING 5. Connect the control (auto shut-down) module, PN 5226640, to the natural colored 8-way connector from instrument panel overlay harness, PN 4362289. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 378 FIGURE 2D - INSTRUMENT PANEL WIRING FIGURE 2F - INSTRUMENT PANEL WIRING 6. Route the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289, to the back of the brake bracket for mating in a later step (Figures 2-B, 2-D, and 2-F). Secure instrument panel overlay harness, PN 4362289, using tie wrap, PN 6015756, to keep it clear of any possible interferences. Only one of the following installation procedures (Step 7) will be used. Take notice of which one applies to the vehicle being repaired. 7. Without Auxiliary Air Conditioning and/or Heater - Jumper Harness PN 4362291 a. Remove instrument panel hood and bezel assembly and remove radio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 379 FIGURE 2D - INSTRUMENT PANEL WIRING b. Route instrument panel jumper harness, PN 4362291, from the back of the brake bracket to the existing 3-way red molded connector. Secure by using existing wiring clips (Figure 2-D). c. Insert the bare bullet terminal (black with white tracer wire) from instrument panel jumper harness, PN 4362291, into the existing 3-way red molded connector from the main instrument panel wiring harness (Figure 2-D). d. Mate the orange colored 1-way connector from instrument panel jumper harness, PN 4362291, to the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). e. Reinstall instrument panel hood and bezel assembly and install radio. FIGURE 2F - INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater and Power Windows - Jumper Harness PN 4362292 a. Disconnect from each other, the two existing brown colored 1-way connectors located near the left instrument panel vent (Figure 2-F). Reconnect these two brown colored 1-way connectors to the two brown colored 1-way connectors from instrument panel jumper harness, PN 4362292 (Figure 2-F). b. Mate the orange colored 1-way connector from the instrument panel jumper harness, PN 4362292, to the orange colored 1-way connector from instrument panel overlay harness, PN 4362289 (Figure 2-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 380 INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater Without Power Windows - Relay Harness PN 4362290 a. Remove instrument panel hood and bezel assembly. Remove radio. b. Install the ignition switch protection relay, PN 4162597, to the back of the brake bracket (mounting location shown in Figure 2-B) and attach instrument panel relay harness, PN 4362290, to relay. c. Secure bare eyelet ground terminal (white wire) from instrument panel relay harness, PN 4362290, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING d. Route the dark blue wire from the instrument panel relay harness, PN 4362290 to the existing 3-way red molded connector using existing wiring clips. Insert bullet terminal (dark blue wire) into red molded connector (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 381 INSTRUMENT PANEL WIRING e. Insert bare bullet terminal (red wire) from instrument panel relay harness, PN 4362290, into the existing 3-way yellow molded connector from the main instrument panel wiring harness (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING f. Mate the orange colored 1-way connector from instrument panel relay harness, PN 4362290, to the colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). g. Install the instrument panel left lower trim panel, instrument panel hood, bezel assembly and radio. C.In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Feed red and yellow molds of body wiring harness, PN 4362293, through slot in the crossmember. Remove existing screw for gauge unit ground. Install eyelet terminal of harness, PN 4362293 (and ground eyelet terminal of 36 gallon tank gauge/pump unit) and torque ground screw to 36 inch pounds. CAUTION: GROUND SCREW MUST BE TIGHTENED SECURELY TO OPERATE ELECTRIC PUMP AND GAUGE UNIT. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 382 FIGURE 3A - BODY WIRING FIGURE 3B - BODY WIRING Install red mold of body harness, PN 4362293, onto red stud of gauge/pump unit. Install yellow mold of harness, PN 4362293, onto black stud of gauge/pump unit (figure 3-a or 3-b). Install molded blade terminal of harness, PN 4362293, onto blade terminal of 22 gallon gauge unit only. NOTE: PREVIOUS GAUGE UNIT GROUND WILL NOT BE USED ON 22 GALLON GAUGE/PUMP UNIT. ON 36 GALLON GAUGE PUMP UNIT, THE GROUND WIRE ON HARNESS PN 4362293 WILL NOT BE USED. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. Set aside the rest of harness, PN 4362293, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. D.Body Wiring Harness Pn 4362293 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 383 FIGURE 3C - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 384 FIGURE 3-F - BODY WIRING 1. Vehicles With 36 Gallon Tank Route harness, PN 4362293, to the right (passenger) side of vehicle along the fuel line tubes and tie wrap (1). At right frame rail, route harness forward to next crossmember (Figures 3-C and 3-E). Tie wrap harness in three (3) places. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 385 FIGURE 3D - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 386 FIGURE 3-F - BODY WIRING Vehicles With 22 Gallon Tank Route harness, PN 4362293, along right frame rail following brake lines (Figures 3-D and 3-E). Tie wrap in two (2) places. NOTE: HARNESS MUST BE ABOVE SHOCK STRUT WITH EITHER 36 OR 22 GALLON TANK. 2. At crossmember, route harness to the left rail following existing brake lines and tie wrap in two (2) places. At left rail, route harness forward through access holes following existing brake lines. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 387 FIGURE 3-F - BODY WIRING NOTE: HARNESS SHOULD BE TIGHT IN THIS AREA THE WRAP IN FOUR (4) PLACES (FIGURE 3-E). 3. At engine compartment, route harness through existing speedometer cable clips to bulkhead connector. If excess wiring exists; loop, tie wrap (2), and install into existing clip (Figure 3-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 388 FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 4. Plug bare terminal of harness, PN 4362293, into cavity #13 of the bulkhead connector (Figure 1-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 389 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 390 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 391 FIGURE 9 - ELECTRIC FUEL PUMP WIRING DIAGRAMW/AUX A/C & HEATER-W/O POWER WINDOWS 5. For all vehicles except those which require a 78 amp alternator package: Reinstall instrument panel side, then engine compartment side of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURES 7, 8, OR 9 FOR OVERALL WIRING DIAGRAMS. E.Engine Compartment Fuel Reservoir/Filter Lnstallation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 392 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER 1. Using template, PN 4418011, mark and drill (from engine side of passenger side chassis rail) two (2) holes .290" diameter (L size drill) as shown in Figure 4-A. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 393 FIGURE 4B - Mounting Fuel Resevoir/Filter 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. NOTE: RUBBER SPLASH SHIELD MAY HAVE TO BE CUT OUT AROUND FUEL RESERVOIR. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube, PN 4306968 (Figure 4-B). 4. Install return hose assembly, PN 4418006, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end (Figure 4-B). 5. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 42O3576. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 394 FIGURE 4B - Mounting Fuel Resevoir/Filter 6. Install one 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the fuel pump outlet tube to the reservoir/filter inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). 7. Install the other 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 8. Tighten all hose clamps to 10 inch pounds. FIGURE 10 9. Type Authorized Modification Label, PN 4275086, as shown in Figure 10 and attach near VECI label. 10. For all models except 1981-1984 equipped with Carter Thermoquad 4BBL carburetor or dual air conditioning units without electrically Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 395 heated rear window defroster. Reconnect battery. Start the engine, and inspect the entire system for fuel leaks and proper wire and hose routing. 11. Reinstall engine cover. F.1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (Pn 4397 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6O22254, (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT, AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6O22254. THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 396 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference with nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose-to-regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. For all models except those equipped with dual air conditioning units, without electrically heated rear window defroster and with 60 amp alternator: 6. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 7. Reinstall engine cover. G.Vehicles Equipped With Dual Air Conditioning Units, Without Electrically Heated Rear Defroster, and With 60 Amp Alternator. I Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 397 HEADLAMP AND DASH WIRING ASSEMBLY 1. Disconnect the battery positive lead (single in-line connection) from the headlamp and dash wiring assembly (Figure 6-A). FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 2. Remove the following wires from the engine compartment side of the bulkhead connector (Figure 6-B). a. Red wire from cavity #39 (ammeter). b. Black wire from cavity #33 (ammeter). Cut off the terminals and wrap tape around each end of both wires to insure that shorting cannot occur. Then tape the wrapped wires back against the main harness. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 398 FIGURE 6-C - 78 AMP ALTERNATOR WIRING 3. Remove the alternator output wire (heavy gauge) from the 60 amp alternator (Figure 6-C). Cut the wire off leaving approximately three (3) inches of wire extending out of the main harness. Tape the end of the lead thoroughly. Then fold and tape the lead back against the main harness to prevent shorting. 4. Remove 60 amp alternator assembly and install 78 amp alternator assembly, PN 4111204, per the service manual alternator replacement procedure. HEADLAMP AND DASH WIRING ASSEMBLY Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 399 FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 5. Beginning at the bulkhead, route and connect the wiring assembly, PN 4362343, as shown in Figure 6-A. Use the existing clip for main harness and tie wrap with three (3) tie wraps, PN 6015756. Insert the two bare terminals from alternator overlay wiring harness, PN 4362343, as shown in Figure 6-B as follows: NOTE: THE 4362343 ALTERNATOR OVERLAY HARNESS WAS MANUFACTURED WITH THE RED AND BLACK WIRES REVERSED. THEREFORE, IT WILL BE NECESSARY TO INSTALL THE BLACK WIRE (LABELED RED) INTO CAVITY #39 (RED WIRE PREVIOUSLY REMOVED), AND THE RED WIRE (LABELED BLACK) INTO CAVITY #33 (BLACK WIRE PREVIOUSLY REMOVED). FAILURE TO REVERSE THESE TWO WIRES WILL RESULT IN THE AMMETER SHOWING THE OPPOSITE CHARGE INDICATION. a. Red wire into cavity #33 (ammeter) - (labeled as black wire). b. Black wire into cavity #39 (ammeter) - (labeled as red wire). 6. Install wiring assembly, PN 4362343, alternator output terminal to new 78 amp alternator. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 400 FIGURE 6A1 7. Connect the battery positive lead and the headlamp and dash wiring assembly lead to those of the alternator overlay wiring assembly, PN 4362343, as shown in circled view of Figure 6-A. 8. Reinstall instrument panel half, then engine compartment half of bulkhead connector and torque to 40 inch pounds. 9. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 10. Reinstall engine cover. POLICY: Reimbursable within the provisions of the warranty and repair manual. TIME ALLOWANCE: Labor Operation No. 14-70-17-94 - All 2.5 Hrs. Optional Equipment: 14-70-17-60 - Carter Thermoquad Carburetor 0.5 Hrs. 14-70-17-61 - With Auxiliary A/C - Without Elec. 0.7 Hrs. Rear Window Defroster 14-70-17-62 - Without Auxiliary A/C 0.3 Hrs. 14-70-17-63 - With Auxiliary A/C - Without 0.4 Hrs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 401 Power Windows FAILURE CODE: AM - Authorized Modification Part List VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 22 GALLON FUEL TANK PACKAGE PART NO. 4397611 QTY PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075432 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Seal - Fuel Tank Gauge 3404451 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 36 GALLON FUEL TANK PACKAGE PART NO. 4397612 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075436 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Gasket - Fuel Tank Sending Unit 4115209 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 402 *It may be necessary to order clamp separately on early released packages. PARTS LIST FUEL PRESSURE REGULATOR PACKAGE FOR 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO.4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 PARTS LIST 78 AMP ALTERNATOR PACKAGE FOR 1981-1985 B MODEL TRUCKS WITH 5.2L OR 5.9L ENGINES PACKAGE PART NO. 4397615 QTY. PART NAME PART NO. 1 78 AMP Alternator Assembly - Complete 4111204 1 Alternator Overlay Wiring Harness 4362343 4 Tie Wrap 6015756 1 Gasket - Bulkhead Connector 4055399 FIGURE 4B - Mounting Fuel Resevoir/Filter 1. Fuel Filter/ Reservoir - 4418012 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 403 2. Screw - Self Tapping - 6022777 (2 Req.) 3. Tube Assy - Fuel Pump to Reservoir - 4306968 4. Return Hose & Sleeve Assy - 4418006 5. Hose Clamps - 6500650 (2 Req.) - 1/4" 6. Hose-Fuel Pump Outlet to Reservoir Inlet - 4203576 7. Hose-Reservoir Outlet to Carburetor or Regulator Fuel Tube - 4203576 8. Hose Clamps - 6500651 (4 Req.) - 5/16" Included but not shown: 2 piece Convolute Tubing - 4279993 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1 SCREW & WASHER - 6022254 2 REGULATOR BRACKET - 4418010 3 REGULATOR - 4418OD9 4 TUBE - REGULATOR TO CARB - 4418008 5 TUBE - RESERVOIR HOSE TO REGULATOR - 4418014 6 SCREW (2 EA.) - REGULATOR TO BRACKET - 6033066 7 CLAMP (5116) - 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 406 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 407 Fuel Gauge Sender: Electrical Diagrams Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 408 Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 409 Fig. 15 Fuel Gauge & Seatbelt Warning System Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 410 Fuel Gauge Sender: Testing and Inspection A hinged float arm in the fuel tank contacts a variable resistor in the gauge sending unit. The varying resistance in the fuel gauge circuit registers on the instrument panel gauge. Resistance in the circuit is lowest when the fuel tank is full and float arm is raised. The resulting high current flow causes the instrument panel gauge to indicate Full. TROUBLESHOOTING 1. Disconnect electrical connector from fuel tank sending unit and attach connector to a known good sending unit. 2. Connect a jumper wire between sending unit fuel pickup tube and a good ground. 3. Secure sending unit float arm in the empty stop position and turn ignition On. Within two minutes, the gauge should read Empty, plus one pointer width or minus two pointer widths. 4. Move float arm and secure in the full stop position. Within two minutes, the gauge should read Full, plus two pointer widths, or minus one pointer width. 5. If fuel gauge does not operate as specified, check the following: a. Wiring and electrical connections between sending unit and connector. b. Wiring and electrical connections between connector and printed circuit board terminals. c. Circuit continuity between printed circuit board terminals and gauge terminals. d. Voltage limiter performance. 6. If fuel gauge operates as specified with known good sending unit, check fuel tank and original sending unit as follows: a. Remove sending unit from fuel tank. b. Connect sending unit wire and jumper wire as previously described. c. If fuel gauge now operates as specified, check sending unit for damage, obstructions or improper installation and correct as necessary. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 415 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 416 Fig. 8 Cargo, Dome & Map Lamps Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Parking Brake Warning Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 421 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 422 Parking Brake Warning Switch: Electrical Diagrams Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 423 Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair Backup Lamp Switch: Service and Repair 1. Unscrew switch from transmission case, allowing fluid to drain into container. 2. Move shift lever to Park and then to Neutral positions and inspect to ensure switch operating lever is centered in switch opening in case. 3. Screw switch into transmission case, then add fluid to the proper level. 4. Check to ensure proper switch operation. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Locations Stop Lamp Switch: Locations On Brake Pedal Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions Stop Lamp Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 433 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 434 Stop Lamp Switch: Electrical Diagrams Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 1 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 435 Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 2 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 436 Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 3 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Page 437 Stop Lamp Switch: Service and Repair EXC. MOTOR HOME 1. Disconnect battery ground cable. 2. Disconnect wiring from switch and remove switch from brake pedal bracket. 3. Reverse procedure to install. 4. To adjust, proceed as follows: a. Loosen switch assembly to pedal bracket attaching screw and slide assembly away from pedal blade or striker plate. b. Push brake pedal down and allow to return to free position. Do not pull brake pedal back at any time. c. Place spacer gauge on pedal blade. Models with speed control use a .070 inch spacer, 1980-83 models less speed control use a .130 inch spacer and 1984-87 models less speed control use a .140 inch spacer. d. Slide switch assembly toward pedal blade until switch plunger is fully depressed against spacer gauge without moving the pedal. e. Tighten the switch bracket attaching screw and remove spacer. Ensure stop light switch does not prevent full pedal return. MOTOR HOME 1. Disconnect battery ground cable. 2. Disconnect wiring from switch and remove switch from bracket. 3. Reverse procedure to install. 4. To adjust, proceed as follows: a. Loosen switch locknut, then the switch until plunger is no longer in contact with pedal blade. b. Disconnect pedal return spring and loosen pushrod locknut. c. Remove pushrod end bolt and pedal return spring bracket assembly. d. Position a .010-.015 inch spacer between pedal blade and pedal stop. e. Turn pushrod in or out until pushrod end bolt can be inserted through pedal blade. Ensure pushrod operates smoothly. f. Install pedal return spring bracket and torque attaching nut to 30 ft. lbs. Torque pushrod locknut to 120 inch lbs. g. Remove spacer and connect pedal return spring, then tighten stop light switch until it contacts pedal blade. Continue to tighten switch 2-1/2 complete turns. h. Tighten switch locknut and ensure proper switch operation. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 442 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 443 Fig. 8 Cargo, Dome & Map Lamps Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 448 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 449 Hazard Warning Switch: Electrical Diagrams Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 1 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 450 Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 2 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 451 Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 3 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 452 Hazard Warning Switch: Service and Repair Turn signal switch retainer removal. Standard columns Lock plate retaining ring removal Turn signal switch removal. Tilt columns Taping turn signal connector and wires 1. Disconnect battery ground cable. 2. On 1983-87 models, remove lower bezel from instrument panel. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 453 3. On all models, remove horn sounder and steering wheel. Refer to ``Horn Sounder & Steering Wheel, Replace'' procedure. 4. On standard columns proceed as follows: a. Remove turn signal lever to switch attaching screw, then the lever. If equipped with speed control, allow lever to hang free. b. Remove switch retainer attaching screws, then the retainer. 5. On tilt columns, proceed as follows: a. Remove plastic cover from lock plate, if equipped. b. Depress lock plate using tool C-4156 or equivalent, then pry retaining ring out of groove using screwdriver. The full load of the cancelling cam spring should not be relieved. If full load is relieved, retaining ring will turn too easily, making removal more difficult. c. Remove lock plate, cancelling cam and spring, then place turn signal lever in right turn position. d. Remove turn signal lever to switch attaching screw, then the lever.If equipped with speed control, allow lever to hang free. e. Remove hazard warning switch knob attaching screw, then the turn signal switch attaching screws. 6. On tilt columns, position steering wheel in midpoint position. 7. On models equipped with column shift, place selector lever in first or third gear position. 8. On all models, remove wire cover attaching clips, then the cover if equipped. 9. Disconnect turn signal electrical connector. Wrap a piece of tape around the connector and wire to prevent snagging during switch removal. 10. Remove turn signal/hazard warning switch assembly by pulling switch up from column while straightening and guiding wires up through column opening. 11. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions Headlight Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 458 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 459 Headlight Switch: Electrical Diagrams Fig. 17 Headlamp Switch & Controlled Interior Lighting Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 460 Fig. 17 Headlamp Switch & Controlled Interior Lighting Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 461 Headlight Switch: Service and Repair 1981 TRAIL DUSTER & 1981-87 RAMCHARGER & CONVENTIONAL CABS 1. Disconnect battery ground cable, then remove cluster face plate. 2. Depress knob and stem release button located on bottom of switch housing, and pull knob and stem assembly from switch. 3. Remove wiper switch knob, then the bezel. 4. Remove switch attaching nut, then disconnect switch electrical connector and remove switch. 5. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair LUXURY TYPE PADDED STEERING WHEEL 1. Disconnect battery ground cable. 2. Pry off pad, then disconnect electrical connector from horn ring terminal. 3. Remove each horn switch to steering wheel retaining screw and lift out horn button switches from wheel. 4. Remove steering wheel nut, then the wheel using a suitable puller. Do not bump or hammer on steering shaft to remove wheel, as damage to shaft may result. 5. Reverse procedure to install. PADDED TYPE EXC. LUXURY TYPE STEERING WHEEL 1. Disconnect battery ground cable. 2. On models with horn pad mounting screws located behind steering wheel spokes, remove screws and the pad. On all other models equipped with horn pad, pry horn pad from wheel. 3. Disconnect horn switch electrical connector. 4. Remove horn switch to retainer attaching screws, then the switch from retainer. 5. Remove steering wheel nut, then the steering wheel using a suitable puller. Do not bump or hammer on steering shaft to remove wheel, as damage to shaft may result. 6. Reverse procedure to install. SPORT STEERING WHEEL 1. Disconnect battery ground cable. 2. Lift horn button off wheel, then disconnect switch electrical connector. 3. Remove steering wheel nut. 4. Remove horn switch to steering wheel attaching screw, then the horn switch. 5. Remove steering wheel using suitable puller. Do not bump or hammer on steering shaft to remove wheel, as damage to shaft may result. 6. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions Interior Light Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 469 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 470 Fig. 8 Cargo, Dome & Map Lamps Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair Turn Signal Switch: Service and Repair Turn Signal/Hazard Warning Switch Turn signal switch retainer removal. Standard columns Lock plate retaining ring removal Turn signal switch removal. Tilt columns Taping turn signal connector and wires 1. Disconnect battery ground cable. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Page 474 2. On 1983-87 models, remove lower bezel from instrument panel. 3. On all models, remove horn sounder and steering wheel. Refer to ``Horn Sounder & Steering Wheel, Replace'' procedure. 4. On standard columns proceed as follows: a. Remove turn signal lever to switch attaching screw, then the lever. If equipped with speed control, allow lever to hang free. b. Remove switch retainer attaching screws, then the retainer. 5. On tilt columns, proceed as follows: a. Remove plastic cover from lock plate, if equipped. b. Depress lock plate using tool C-4156 or equivalent, then pry retaining ring out of groove using screwdriver. The full load of the cancelling cam spring should not be relieved. If full load is relieved, retaining ring will turn too easily, making removal more difficult. c. Remove lock plate, cancelling cam and spring, then place turn signal lever in right turn position. d. Remove turn signal lever to switch attaching screw, then the lever.If equipped with speed control, allow lever to hang free. e. Remove hazard warning switch knob attaching screw, then the turn signal switch attaching screws. 6. On tilt columns, position steering wheel in midpoint position. 7. On models equipped with column shift, place selector lever in first or third gear position. 8. On all models, remove wire cover attaching clips, then the cover if equipped. 9. Disconnect turn signal electrical connector. Wrap a piece of tape around the connector and wire to prevent snagging during switch removal. 10. Remove turn signal/hazard warning switch assembly by pulling switch up from column while straightening and guiding wires up through column opening. 11. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 481 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 486 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations Coolant Temperature Sensor/Switch (For Computer): Component Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 489 Coolant Temperature Sensor/Switch (For Computer): Connector Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 490 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Coolant Temperature Switch Coolant Temperature Sensor/Switch (For Computer): Description and Operation Coolant Temperature Switch Fig. 4 Switches & sensors location. V8 engine On V8 engines the coolant switch is located on the front of the intake manifold, Fig. 4. It operates by supplying a signal to the computer when the engine coolant temperature is below 150~ F. This information is required to prevent a change in air fuel ratio until engine operation temperature is reached except there is no control of canister purging. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Coolant Temperature Switch > Page 493 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Description The coolant temperature sensor measures temperature of the engine coolant. The coolant temperature sensor is mounted in the thermostat housing or in water passage of intake manifold. The sensor monitors engine coolant (operating) temperature. It supplies the logic module with a voltage signal which varies with coolant temperature. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 498 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control Crankshaft Position Sensor: Service and Repair RWD W/ Electronic Spark Control Removal & Installation Removal 1. Disconnect vacuum line at distributor, if equipped. 2. Disconnect distributor pickup lead(s) at wiring harness connector, then remove distributor cap. 3. Mark position of rotor on distributor body and engine block surface so that distributor can be installed in the same position. 4. Remove hold-down and/or bolt and lift distributor from engine. Installation 1. If engine was cranked after distributor was removed from engine, rotate crankshaft to bring No. 1 piston up on its compression stroke and align timing mark on crankshaft pulley with ``O'' (TDC) mark on timing cover. 2. With distributor gasket or O-ring in place, hold distributor over mounting pad. 3. Turn rotor to a position just ahead of the No. 1 distributor cap terminal. 4. Install distributor, engaging distributor gear with camshaft drive gear on 6 cylinder engines. On V-8 engines, engage tang of distributor shaft with slot in oil pump drive gear. With distributor fully seated on engine, rotor should be under No. 1 cap terminal. 5. Install distributor hold-down and/or bolt, distributor cap, pickup lead(s) and vacuum line. 6. Adjust ignition timing to specifications found in the Tune Up section. Distributor Shaft & Bushing Wear Test 1. Remove distributor from vehicle and clamp distributor in a vise. Use extreme caution not to damage distributor. 2. Attach a dial indicator to housing so plunger rests against reluctor sleeve. 3. Place a wire loop around reluctor sleeve and hook a spring scale on the other end of the loop. Apply a 1-1/2 lb. pull toward dial indicator. Apply a 1 lb. pull away from dial indicator and read movement on indicator. 4. Movement must not exceed .006 inch. If movement exceeds limit, replace either housing or shaft to bring movement back within tolerance. Distributor Disassembly 1. Remove rotor and vacuum advance unit, if equipped Fig. 14. 2. Remove reluctor by prying up from bottom of reluctor using two screwdrivers with a maximum blade width of 7/16 in. Use care not to damage or distort reluctor teeth. 3. Remove two screws and lockwashers attaching lower plate to distributor housing, then lift out lower plate, upper plate and pickup coil as an assembly. Do not remove distributor cap clamp springs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 501 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 4. On eight cylinder units, if distributor housing, shaft, reluctor sleeve or governor weights are to be replace, proceed as follows: a. Remove distributor shaft retaining pin and slide retainer off end of shaft. b. If necessary, use a file to clean burrs from around pin hole area on shaft, then remove lower thrust washer. c. Push shaft upward and remove from distributor housing. Distributor Assembly Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 502 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 1. Lubricate and test operation of governor weights. Inspect weight springs for distortion and bearing surfaces and pins for damage. 2. Lubricate upper thrust washer and install onto shaft. Install shaft into housing. 3. On eight cylinder units, install distributor shaft retainer and pin, Fig. 14. 4. On all units, install lower plate, upper plate and pickup coil assembly. 5. Attach vacuum advance unit to pickup plate, then install vacuum advance unit attaching screws and washers. 6. Position reluctor keeper pin into place on reluctor sleeve, then slide reluctor down reluctor sleeve and press firmly into position. Install keeper pin. 7. Lubricate felt pad located in top of reluctor sleeve with one drop of light engine oil, then install rotor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 503 Crankshaft Position Sensor: Service and Repair RWD W/O Electronic Spark Control Removal & Installation Removal 1. Disconnect vacuum line at distributor, if equipped. 2. Disconnect distributor pickup lead(s) at wiring harness connector, then remove distributor cap. 3. Mark position of rotor on distributor body and engine block surface so that distributor can be installed in the same position. 4. Remove hold-down and/or bolt and lift distributor from engine. Installation 1. If engine was cranked after distributor was removed from engine, rotate crankshaft to bring No. 1 piston up on its compression stroke and align timing mark on crankshaft pulley with ``O'' (TDC) mark on timing cover. 2. With distributor gasket or O-ring in place, hold distributor over mounting pad. 3. Turn rotor to a position just ahead of the No. 1 distributor cap terminal. 4. Install distributor, engaging distributor gear with camshaft drive gear on 6 cylinder engines. On V-8 engines, engage tang of distributor shaft with slot in oil pump drive gear. With distributor fully seated on engine, rotor should be under No. 1 cap terminal. 5. Install distributor hold-down and/or bolt, distributor cap, pickup lead(s) and vacuum line. 6. Adjust ignition timing to specifications found in the Tune Up section. Distributor Shaft & Bushing Wear Test 1. Remove distributor from vehicle and clamp distributor in a vise. Use extreme caution not to damage distributor. 2. Attach a dial indicator to housing so plunger rests against reluctor sleeve. 3. Place a wire loop around reluctor sleeve and hook a spring scale on the other end of the loop. Apply a 1-1/2 lb. pull toward dial indicator. Apply a 1 lb. pull away from dial indicator and read movement on indicator. 4. Movement must not exceed .006 inch. If movement exceeds limit, replace either housing or shaft to bring movement back within tolerance. Distributor Disassembly 1. Remove rotor and vacuum advance unit, if equipped Fig. 14. 2. Remove reluctor by prying up from bottom of reluctor using two screwdrivers with a maximum blade width of 7/16 in. Use care not to damage or distort reluctor teeth. 3. Remove two screws and lockwashers attaching lower plate to distributor housing, then lift out lower plate, upper plate and pickup coil as an assembly. Do not remove distributor cap clamp springs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 504 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 4. On eight cylinder units, if distributor housing, shaft, reluctor sleeve or governor weights are to be replace, proceed as follows: a. Remove distributor shaft retaining pin and slide retainer off end of shaft. b. If necessary, use a file to clean burrs from around pin hole area on shaft, then remove lower thrust washer. c. Push shaft upward and remove from distributor housing. Distributor Assembly Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 505 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 1. Lubricate and test operation of governor weights. Inspect weight springs for distortion and bearing surfaces and pins for damage. 2. Lubricate upper thrust washer and install onto shaft. Install shaft into housing. 3. On eight cylinder units, install distributor shaft retainer and pin, Fig. 14. 4. On all units, install lower plate, upper plate and pickup coil assembly. 5. Attach vacuum advance unit to pickup plate, then install vacuum advance unit attaching screws and washers. 6. Position reluctor keeper pin into place on reluctor sleeve, then slide reluctor down reluctor sleeve and press firmly into position. Install keeper pin. 7. Lubricate felt pad located in top of reluctor sleeve with one drop of light engine oil, then install rotor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Charge Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Charge Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 509 Charge Temperature Switch Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Charge Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 510 Charge Temperature Sensor: Description and Operation Fig. 4 Switches & sensors location. V8 engine The CTS, Fig. 4, is used on eight cylinder engines and is located in the intake manifold No. 8 runner on eight cylinder engines. When the incoming air fuel mixture is below 60° F., the CTS will close, allowing no EGR timer function, no EGR valve operation and the air injection directed upstream into the exhaust manifold. When incoming air-fuel mixture is above 60° F., the CTS will open allowing EGR timer to expire, the EGR valve to operate and air injection switched downstream into the exhaust system. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Charge Temperature Switch <--> [Intake Air Temperature Switch] > Component Information > Locations Charge Temperature Switch: Locations Engine Mounted Switches & Sensors. Upper RH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Component Locations Detonation (Knock) Sensor: Component Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Component Locations > Page 518 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Page 519 Detonation (Knock) Sensor: Description and Operation Fig. 12 Detonation sensor location. V8 engine The detonation sensor, Fig. 12, is used on V8 engines only and is located in the intake manifold. It signals the computer when detonation occurs so that the ignition timing can be retarded. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications All models with TBI. Apply 5" (125mm) Hg to unit and record output voltage. Apply 20" (500mm) Hg to unit, the difference in voltage should be 2.3 - 2.9. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 523 Manifold Pressure/Vacuum Sensor: Locations Combustion Control Computer Location. Upper RH Side Of Engine Applicable to: 1981-84 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 524 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 7 Spark control computer & vacuum transducer location. V8 engine The vacuum transducer is located on the computer and it provides the computer with information on engine vacuum, Fig. 7. It is used to control spark advance and air fuel ratios. And indicates engine load. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Engine Mounted Switches & Sensors. Lower RH Side Of Engine Applicable to: V8 Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 530 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 531 Oxygen Sensor: Description and Operation Fig. 7 Spark control computer & vacuum transducer location. V8 engine To provide the EFC system with an indication of the exhaust gas composition, an oxygen sensor is threaded into the exhaust manifold and is exposed directly to exhaust gas stream, Fig. 7. The sensor is sensitive to the presence of or lack of oxygen. With an oxygen deficiency in the exhaust gas, outside oxygen diffuses through the sensor, acting as an electrolyte and generating a voltage. The oxygen sensor is basically a galvanic battery consisting of a cylindrical electrolyte element of zirconium dioxide which is coated inside and out with platinum. The outer platinum electrode is exposed to atmosphere, while the inner is exposed to the hot exhaust gases. A porous ceramic (spinel) coating protects the platinum against damage. When heated to operating temperature by the hot exhaust gases, the sensor generates a voltage. If the oxygen is high, a low voltage (below .45 volts) will be produced. When the oxygen content is low (rich mixture), a high voltage (.45 to 1 volt) will be produced. This relationship between available oxygen and sensor output voltage causes the sensor to function as a rich-lean switch. The sensor output voltage is used by the Feedback Carburetor Controller to calculate and adjust the air-fuel mixture as needed for optimum catalytic converter operation. The sensor's internal impedance, output voltage and time response are all functions of temperature. This temperature dependency is important during cold starts and other low temperature operating modes. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Throttle Body Temperature Sensor] > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Carburetor Switch <--> [Throttle Full Close Switch] > Component Information > Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Carburetor Switch <--> [Throttle Full Close Switch] > Component Information > Locations > Page 538 Carburetor Switch: Description and Operation Fig. 4 Switches & sensors location. V8 engine The carburetor switch, Fig. 4, is located on the end of the idle stop and it signals the computer when the engine is at idle. Whenever the curb idle screw touches the carburetor switch, there will be no additional advance from the vacuum transducer or changing of the carburetor air fuel ratio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 543 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vacuum Switch > Component Information > Description and Operation Vacuum Switch: Description and Operation Fig. 7 Spark control computer & vacuum transducer location. V8 engine The vacuum transducer is located on the computer and it provides the computer with information on engine vacuum, Fig. 7. It is used to control spark advance and air fuel ratios. And indicates engine load. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Distance Sensor <--> [Vehicle Speed Sensor] > Component Information > Diagrams > Diagram Information and Instructions Distance Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Distance Sensor <--> [Vehicle Speed Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 551 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Choke Temperature Control Switch > Component Information > Locations Choke Temperature Control Switch: Locations Upper RH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Intake Air Temperature (IAT) Sensor <--> [Throttle Body Temperature Sensor] > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Carburetor Switch <--> [Throttle Full Close Switch] > Component Information > Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Carburetor Switch <--> [Throttle Full Close Switch] > Component Information > Locations > Page 562 Carburetor Switch: Description and Operation Fig. 4 Switches & sensors location. V8 engine The carburetor switch, Fig. 4, is located on the end of the idle stop and it signals the computer when the engine is at idle. Whenever the curb idle screw touches the carburetor switch, there will be no additional advance from the vacuum transducer or changing of the carburetor air fuel ratio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 567 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 573 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 578 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control Crankshaft Position Sensor: Service and Repair RWD W/ Electronic Spark Control Removal & Installation Removal 1. Disconnect vacuum line at distributor, if equipped. 2. Disconnect distributor pickup lead(s) at wiring harness connector, then remove distributor cap. 3. Mark position of rotor on distributor body and engine block surface so that distributor can be installed in the same position. 4. Remove hold-down and/or bolt and lift distributor from engine. Installation 1. If engine was cranked after distributor was removed from engine, rotate crankshaft to bring No. 1 piston up on its compression stroke and align timing mark on crankshaft pulley with ``O'' (TDC) mark on timing cover. 2. With distributor gasket or O-ring in place, hold distributor over mounting pad. 3. Turn rotor to a position just ahead of the No. 1 distributor cap terminal. 4. Install distributor, engaging distributor gear with camshaft drive gear on 6 cylinder engines. On V-8 engines, engage tang of distributor shaft with slot in oil pump drive gear. With distributor fully seated on engine, rotor should be under No. 1 cap terminal. 5. Install distributor hold-down and/or bolt, distributor cap, pickup lead(s) and vacuum line. 6. Adjust ignition timing to specifications found in the Tune Up section. Distributor Shaft & Bushing Wear Test 1. Remove distributor from vehicle and clamp distributor in a vise. Use extreme caution not to damage distributor. 2. Attach a dial indicator to housing so plunger rests against reluctor sleeve. 3. Place a wire loop around reluctor sleeve and hook a spring scale on the other end of the loop. Apply a 1-1/2 lb. pull toward dial indicator. Apply a 1 lb. pull away from dial indicator and read movement on indicator. 4. Movement must not exceed .006 inch. If movement exceeds limit, replace either housing or shaft to bring movement back within tolerance. Distributor Disassembly 1. Remove rotor and vacuum advance unit, if equipped Fig. 14. 2. Remove reluctor by prying up from bottom of reluctor using two screwdrivers with a maximum blade width of 7/16 in. Use care not to damage or distort reluctor teeth. 3. Remove two screws and lockwashers attaching lower plate to distributor housing, then lift out lower plate, upper plate and pickup coil as an assembly. Do not remove distributor cap clamp springs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 581 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 4. On eight cylinder units, if distributor housing, shaft, reluctor sleeve or governor weights are to be replace, proceed as follows: a. Remove distributor shaft retaining pin and slide retainer off end of shaft. b. If necessary, use a file to clean burrs from around pin hole area on shaft, then remove lower thrust washer. c. Push shaft upward and remove from distributor housing. Distributor Assembly Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 582 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 1. Lubricate and test operation of governor weights. Inspect weight springs for distortion and bearing surfaces and pins for damage. 2. Lubricate upper thrust washer and install onto shaft. Install shaft into housing. 3. On eight cylinder units, install distributor shaft retainer and pin, Fig. 14. 4. On all units, install lower plate, upper plate and pickup coil assembly. 5. Attach vacuum advance unit to pickup plate, then install vacuum advance unit attaching screws and washers. 6. Position reluctor keeper pin into place on reluctor sleeve, then slide reluctor down reluctor sleeve and press firmly into position. Install keeper pin. 7. Lubricate felt pad located in top of reluctor sleeve with one drop of light engine oil, then install rotor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 583 Crankshaft Position Sensor: Service and Repair RWD W/O Electronic Spark Control Removal & Installation Removal 1. Disconnect vacuum line at distributor, if equipped. 2. Disconnect distributor pickup lead(s) at wiring harness connector, then remove distributor cap. 3. Mark position of rotor on distributor body and engine block surface so that distributor can be installed in the same position. 4. Remove hold-down and/or bolt and lift distributor from engine. Installation 1. If engine was cranked after distributor was removed from engine, rotate crankshaft to bring No. 1 piston up on its compression stroke and align timing mark on crankshaft pulley with ``O'' (TDC) mark on timing cover. 2. With distributor gasket or O-ring in place, hold distributor over mounting pad. 3. Turn rotor to a position just ahead of the No. 1 distributor cap terminal. 4. Install distributor, engaging distributor gear with camshaft drive gear on 6 cylinder engines. On V-8 engines, engage tang of distributor shaft with slot in oil pump drive gear. With distributor fully seated on engine, rotor should be under No. 1 cap terminal. 5. Install distributor hold-down and/or bolt, distributor cap, pickup lead(s) and vacuum line. 6. Adjust ignition timing to specifications found in the Tune Up section. Distributor Shaft & Bushing Wear Test 1. Remove distributor from vehicle and clamp distributor in a vise. Use extreme caution not to damage distributor. 2. Attach a dial indicator to housing so plunger rests against reluctor sleeve. 3. Place a wire loop around reluctor sleeve and hook a spring scale on the other end of the loop. Apply a 1-1/2 lb. pull toward dial indicator. Apply a 1 lb. pull away from dial indicator and read movement on indicator. 4. Movement must not exceed .006 inch. If movement exceeds limit, replace either housing or shaft to bring movement back within tolerance. Distributor Disassembly 1. Remove rotor and vacuum advance unit, if equipped Fig. 14. 2. Remove reluctor by prying up from bottom of reluctor using two screwdrivers with a maximum blade width of 7/16 in. Use care not to damage or distort reluctor teeth. 3. Remove two screws and lockwashers attaching lower plate to distributor housing, then lift out lower plate, upper plate and pickup coil as an assembly. Do not remove distributor cap clamp springs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 584 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 4. On eight cylinder units, if distributor housing, shaft, reluctor sleeve or governor weights are to be replace, proceed as follows: a. Remove distributor shaft retaining pin and slide retainer off end of shaft. b. If necessary, use a file to clean burrs from around pin hole area on shaft, then remove lower thrust washer. c. Push shaft upward and remove from distributor housing. Distributor Assembly Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 585 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 1. Lubricate and test operation of governor weights. Inspect weight springs for distortion and bearing surfaces and pins for damage. 2. Lubricate upper thrust washer and install onto shaft. Install shaft into housing. 3. On eight cylinder units, install distributor shaft retainer and pin, Fig. 14. 4. On all units, install lower plate, upper plate and pickup coil assembly. 5. Attach vacuum advance unit to pickup plate, then install vacuum advance unit attaching screws and washers. 6. Position reluctor keeper pin into place on reluctor sleeve, then slide reluctor down reluctor sleeve and press firmly into position. Install keeper pin. 7. Lubricate felt pad located in top of reluctor sleeve with one drop of light engine oil, then install rotor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 590 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 591 Ignition Switch: Electrical Diagrams Fig. 19 Ignition Switch Less Tilt Wheel & Starter Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 592 Fig. 19 Ignition Switch Less Tilt Wheel & Starter Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 593 Fig. 20 Ignition Switch With Tilt Wheel Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 594 Ignition Switch: Service and Repair Fig. 1 Lock cylinder removal. Less tilt steering wheel MODELS LESS TILT STEERING 1. Disconnect battery ground cable and remove turn signal switch as outlined in this chapter. 2. Remove ignition key lamp assembly attaching screws, then the assembly. 3. Remove snap ring from upper end of steering shaft. 4. Remove bearing housing to lock housing attaching screws, then the bearing housing from the shaft. 5. Remove buzzer switch attaching screws, then the buzzer switch, if equipped. 6. Remove lock lever guide plate attaching screws, then the lock plate. 7. Place lock cylinder in the "Lock" position and remove key. Using a suitable tool, depress spring loaded lock retainer and pull lock cylinder from housing bore. 8. Remove ignition switch attaching screws, then the ignition switch. 9. Reverse procedure to install. Fig. 2 Lock cylinder removal. W/tilt steering wheel MODELS WITH TILT STEERING Fig. 2 Lock cylinder removal. W/tilt steering wheel Ignition Lock, Replace Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 595 The ignition switch and lock assembly are separate units and must be replaced individually. 1. Disconnect battery ground cable and remove turn signal switch as outlined in this chapter. 2. Place lock cylinder in the "Lock" position and remove key. Insert suitable tool into slot next to switch mounting screw boss. 3. Depress spring latch at bottom of slot, then remove lock. 4. To install ignition lock, place lock cylinder in the "Lock" position and remove key. Install lock cylinder assembly into housing, then press inward and move switch actuator rod up and down to align parts. When parts align, the lock cylinder will move inward and a spring loaded retainer will snap into place, locking cylinder into housing. Ignition Switch, Replace The ignition switch is located on the top of the steering column under the instrument panel. To replace it, the steering column should be lowered as follows: 1. Disconnect shift indicator link. 2. Remove nuts securing bracket to dash panel and carefully lower column. 3. Disconnect electrical connector from switch. Ensure switch is in "Accessory" position. 4. Remove switch attaching screws, then the switch. 5. To install ignition switch, place switch slider and lock in the "Accessory" position. 6. Fit actuator rod into switch and assemble to column. 7. Complete assembly in reverse of removal procedure. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Component Locations Detonation (Knock) Sensor: Component Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Component Locations > Page 600 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Page 601 Detonation (Knock) Sensor: Description and Operation Fig. 12 Detonation sensor location. V8 engine The detonation sensor, Fig. 12, is used on V8 engines only and is located in the intake manifold. It signals the computer when detonation occurs so that the ignition timing can be retarded. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations Clutch Switch: Locations On Clutch Pedal Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 610 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 611 Ignition Switch: Electrical Diagrams Fig. 19 Ignition Switch Less Tilt Wheel & Starter Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 612 Fig. 19 Ignition Switch Less Tilt Wheel & Starter Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 613 Fig. 20 Ignition Switch With Tilt Wheel Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Page 614 Ignition Switch: Service and Repair Fig. 1 Lock cylinder removal. Less tilt steering wheel MODELS LESS TILT STEERING 1. Disconnect battery ground cable and remove turn signal switch as outlined in this chapter. 2. Remove ignition key lamp assembly attaching screws, then the assembly. 3. Remove snap ring from upper end of steering shaft. 4. Remove bearing housing to lock housing attaching screws, then the bearing housing from the shaft. 5. Remove buzzer switch attaching screws, then the buzzer switch, if equipped. 6. Remove lock lever guide plate attaching screws, then the lock plate. 7. Place lock cylinder in the "Lock" position and remove key. Using a suitable tool, depress spring loaded lock retainer and pull lock cylinder from housing bore. 8. Remove ignition switch attaching screws, then the ignition switch. 9. Reverse procedure to install. Fig. 2 Lock cylinder removal. W/tilt steering wheel MODELS WITH TILT STEERING Fig. 2 Lock cylinder removal. W/tilt steering wheel Ignition Lock, Replace Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Page 615 The ignition switch and lock assembly are separate units and must be replaced individually. 1. Disconnect battery ground cable and remove turn signal switch as outlined in this chapter. 2. Place lock cylinder in the "Lock" position and remove key. Insert suitable tool into slot next to switch mounting screw boss. 3. Depress spring latch at bottom of slot, then remove lock. 4. To install ignition lock, place lock cylinder in the "Lock" position and remove key. Install lock cylinder assembly into housing, then press inward and move switch actuator rod up and down to align parts. When parts align, the lock cylinder will move inward and a spring loaded retainer will snap into place, locking cylinder into housing. Ignition Switch, Replace The ignition switch is located on the top of the steering column under the instrument panel. To replace it, the steering column should be lowered as follows: 1. Disconnect shift indicator link. 2. Remove nuts securing bracket to dash panel and carefully lower column. 3. Disconnect electrical connector from switch. Ensure switch is in "Accessory" position. 4. Remove switch attaching screws, then the switch. 5. To install ignition switch, place switch slider and lock in the "Accessory" position. 6. Fit actuator rod into switch and assemble to column. 7. Complete assembly in reverse of removal procedure. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair Neutral Safety Switch: Service and Repair 1. Unscrew switch from transmission case, allowing fluid to drain into container. 2. Move shift lever to Park and then to Neutral positions and inspect to ensure switch operating lever is centered in switch opening in case. 3. Screw switch into transmission case, then add fluid to the proper level. 4. Check to ensure proper switch operation. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations Door Components The power window switch is located near the top of each door panel. The master switch on the drivers door can also control the other door(s). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 623 Power Window Switch: Testing and Inspection Window Switch Connector 1. Remove the left power window switch from the trim panel and remove the wiring harness from the back of the switch. Connect jumper wires as shown to the left switch harness forcing the windows to operate in each direction. ^ If the window motors operate properly, the left switch is defective. ^ If the left window motor does not operate properly, the window motor or wiring may be defective. ^ If the right window motor does not operate properly, go to step 2. 2. Remove the right power window switch from the trim panel and remove the wiring harness from the back of the switch. Connect the jumper wires to the right switch harness as shown and test using jumper wires at the left door harness. ^ If the right window motor operates properly, the right window switch is defective. ^ If the right window motor does not operate properly, the right window motor or wiring may be defective. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 624 Power Window Switch: Service and Repair Door Components Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 625 Power Window Switch Replacement Disconnect the battery negative terminal. Using a small flat blade screwdriver, carefully pry the power window switch from the door panel bezel. Remove the wire connector from the power window switch by carefully prying between the connector and the back of the switch. Install by pressing the wire connector onto the switch and pressing the switch into the door panel bezel. Connect the battery negative terminal and test the system for proper operation. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair Wiper Switch: Service and Repair 1981 TRAIL DUSTER & 1981-87 RAMCHARGER & CONVENTIONAL CAB 1. Disconnect battery ground cable, then remove cluster face plate. 2. Depress head light knob and stem release button located on bottom of switch housing and pull knob and stem assembly from switch. 3. Pull wiper switch knob off wiper switch. 4. Remove bezel attaching screws, then the bezel. 5. Remove four wiper switch attaching screws. 6. Disconnect switch electrical connectors, then remove switch. 7. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 634 Alignment: Service and Repair Fig. 7 Alignment adjustment locations & directions. Cam bolt type Fig. 8 Alignment adjustment locations & directions. Pivot bolt type CASTER & CAMBER, ADJUST Independent Front Suspension Front suspension height must be checked and corrected as necessary prior to checking wheel alignment. 1. Remove all foreign material from exposed threads of cam adjusting bolt nuts or pivot bar adjusting bolt nuts. 2. Record initial camber and caster readings before loosening cam bolt nuts or pivot bar bolt nuts. 3. On vehicles using cam bolts, the camber and caster is adjusted by loosening the cam bolt nuts and turning the cam bolts as necessary until the desired setting is obtained. On vehicles using pivot bars, tool C-4581 or equivalent is required to adjust caster and camber. When performing adjustments, the camber settings should be held as close as possible to the "desired" setting, and the caster setting should be held as nearly equal as possible on both wheels. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 635 Fig. 9 Caster angle adjustment. Exc. independent front suspension Exc. Independent Front Suspension No adjustment is provided for camber. If camber is not within specifications, axle or steering knuckle is bent and should be replaced. Caster may be adjusted by inserting a wedge between the spring and axle. To increase caster insert wedge so that the thick part faces rear of vehicle. To decrease caster insert wedge so that the thick end is toward front of vehicle. TOE-IN, ADJUST With the front wheels in straight ahead position, loosen the clamps at each end of both adjusting tubes. Adjust toe-in by turning the tie rod sleeve which will "center" the steering wheel spokes. If the steering wheel was centered, make the toe-in adjustment by turning both sleeves an equal amount. Position sleeve clamps so ends do not align in the sleeve slot. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pump Pressure ............................................................................................................................ ........................................................ 4.75 psi - 6.25 psi Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package Technical Service Bulletin # 250485 Date: 850506 High Altitude Conversion Package Models 1985 Light Duty Domestic Trucks Subject High Altitude Conversion Packages & Adjustment for Improved Engine Performance Index EMISSIONS Date May 6, 1985 No.. 25-04-85 P-1522-C Packages are now available to accommodate a customer who wishes to convert his 1985 low altitude vehicle for improved high altitude (over 4,000 feet above sea level) engine performance. Vehicles with the low altitude package transferred to service in high altitude areas may exhibit undesirable driveability. However, the installation of a high altitude conversion package is voluntary and at the customer's expense. The high altitude field conversion packages and procedures outlined below have been authorized on the following 1985 non-altitude equipped engine families in service at altitudes above 4,000 feet above sea level. CONVERSION INSTRUCTIONS Sea Level to Altitude FIGURE 1 - Vehicle Emission Control Information Label IMPORTANT: IN SOME OF THE CONVERSION PROCEDURES YOU WILL BE REQUIRED TO INSTALL A NEW VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL PN 4275084. THIS LABEL HAS TWO AREAS THAT ARE IMPACT IMPRINTABLE WITH A TYPEWRITER (SEE FIGURE 1). If you are required to readjust timing, curb idle speed, or fast idle speed to a specification different than the original VECI label specification, then just type in the new specification after the subject operation. If you are asked to refer to the original VECI label specifications, type in on the right hand side of the label "Refer to Original VECI Label." Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 644 In every case where this label is used, type in after - AUTHORITY OF Technical Service Bulletin #25-04-85, and your dealer code below. Label PN 4275084 is available from Parts Supply. FIGURE 2 - Vehicle Emission Control Information Label The engine family chart below will help identify the appropriate parts to be installed by recording body style and engine family from the original VECI label. This chart cross references the EPA engine family with the engine application used in the accompanying instructions (refer to Figure 2). EPA Engine Family Engine Application (Found on VECI Label) 2.2L-2V Federal FCR2.2T2AAB6 2.2L-2V 50 States FCR2.2T2HBM9 2.6L-2V Federal FCR2.6T2AAB8 3.7L-1V Federal FCR3.7T1BBA0 5.2L-2V 50 States FCR5.2T2HBN1 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 645 5.2L-2V Federal FCR5.2T2BBF6 5.9L-4V Federal FCR5.9T4BBF1 POLICY: Information only 1985 2.2L-2V Light Duty Trucks All Models With Federal Emissions Package (49 States) Dodge Ram Van, Dodge Caravan, Plymouth Voy Consisting of: 1 - #211 Primary Main Jet PN 4293797 1 - #215 Secondary Main Jet PN 4240006 1 - #180 Primary High Speed Bleed PN 4342920 1 - #210 Secondary High Speed Bleed PN 4342921 1 - Carburetor Air Horn Gasket PN 4293846 INSTRUCTIONS FIGURE 1. Holley 5220 Primary Main Metering Jet #211 FIGURE 2. Holley 5220 Secondary Main Metering Jet #223 - Remove carburetor air horn. - Remove primary and secondary main metering jets. Refer to Figures 1 and 2. - Install #211 primary main metering jet PN 4293797. - Install #215 secondary main metering jet PN 4240006. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 646 FIGURE 3. Holley 5220 Primary High Speed Bleed #180 FIGURE 4. Holley 5220 Secondary High Speed Bleed #210 - Remove primary and secondary high speed bleeds. Refer to Figures 3 and 4. - Install #180 primary high speed bleed PN 4342920. - Install #210 secondary high speed bleed PN 4342921. FIGURE 5. Holley 5220 Power Valve Location - Turn power valve (Figure 5) two full turns counterclockwise (lean). - Reinstall air horn with new air horn gasket PN 4293846. Start engine and check for leaks. - Warm up engine and set idle speed to that specified on the VECI label. - Type in changes made on Emission Update Label PN 4275084 and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 647 1985 2.2L-2V Light Duty Truck Dodge Ram Van, Dodge Caravan & Plymouth Voyager Only Equipped With "50 States" Emission Package Consisting of: 1 - Carburetor (manual or automatic PN 4342891 transmission) Also order conversion hardware package. 1 - Hardware Package PN 4342950 Consisting of: 1 - Carburetor Base Gasket PN 4095975 1 - H.A.C. PN 4306202 1 - Hose Routing Diagram NPN 1 - Mounting Bracket (H.A.C.) PN 4105199 1 - H.A.C. Hose Harness NPN 3 - Mounting Screws NPN INSTRUCTIONS - Remove carburetor per instructions in appropriate engine performance/electrical shop manual. - Install new carburetor with new base gasket. FIGURE 6 - High Altitude Compensator Mounting - Install altitude compensator with bracket (Figure 6). - Install altitude compensator vacuum hose harness, route as shown in hose routing diagram (Figure 6). - Warm up engine. - Set engine idle speed to specified VECI label specification. - Set high fast idle on Step 3 (lowest) to specification. - Double check hose routing and installation of fuel lines. - Type in changes made on the Emission Update Label PN 4275084 and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 648 1985 2.6L-2V Light Duty Truck All Models With Federal Emissions Package (49 States) Consisting of: 1 - Carburetor Jet Kit PN MD088294 containing: #110 Primary Main Jet #175 Secondary Main Jet #100 Primary Air Bleed Jet #120 Secondary Air Bleed Jet 1 - Float Chamber Cover Gasket PN MD608639 1 - Choke Cover Screw Kit PN MD606977 1 - Carburetor Flange Gasket PN MD025344 INSTRUCTIONS - Remove carburetor from engine and take off air horn per instructions in appropriate service manual. FIGURE 7 - Mikuni Jet Locations - Remove primary and secondary main jets as shown in Figure 7. - Install #110 primary main jet and #175 secondary main jet in the primary and secondary pedestals. - Reinstall air horn on carburetor using new air horn gasket PN MD608639 and choke cover screw kit PN MD606977. FIGURE 8 - Mikuni Air Bleed Jet Locations - Remove primary and secondary air bleed jets shown in Figure 8. - Prepare carburetor for propane idle set by drilling out concealment plug. - Install #120 secondary air bleed jet and #100 primary air bleed jet. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 649 - Reinstall carburetor on engine using a new carburetor flange gasket, PN MD025344. - Remove vacuum controlled orificed tank vapor valve (VCOTV) and the vacuum/line(s) to the valve. - Remove the 3/16" tank vent line from the vapor canister and replace with 24" of 3/16" tank vent line and route directly to steel tank vent tube. - Remove the manifold vacuum line from the manifold vacuum tee (originally to the VCOTV) and cap the tee. - Remove the EGR delay valve at the corresponding EGR and carburetor ports and replace with 8" of bulk 3/16" vacuum line from stock. - Start engine and warm up to operating temperature. - Set idle rpm (curb) to 850 rpm and propane enriched rpm to 950 rpm. - Set throttle kicker rpm to 1050 rpm. FIGURE 9 - Authorized Modifications Label - Type in changes made on Authorized Modification Label, PN 4275086 (Figure 9), and affix to engine compartment next to VECI label. 1985 3.7L-1V Light Duty Trucks All Models With Federal Emission Package (49 States) Consisting of: 1 - #611 Main Metering Jet PN 3837520 1 - Carburetor Air Horn Gasket PN 4267140 INSTRUCTIONS - Remove carburetor. - Remove air horn from carburetor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 650 FIGURE 10 - Main Metering Jet Location - Remove existing main metering jet (Figure 10). - Install #611 main metering jet PN 3837520. - Reinstall air horn with new air horn gasket PN 4267140. - Drill out concealment plug and prepare carburetor for propane idle set. - Per instructions in appropriate service manual, perform a propane idle set. Reset the propane/curb idle speeds to 775/750 for manuals and 800/775 for automatics. - Reset HFI to 1600 on Step 2. - Reset choke vacuum kick to 0.120". - Reset idle solenoid speed to 850 rpm (manual transmission) or 875 (automatic transmission). - Type in changes made on Emission Update Label and affix in engine compartment next to VECI label. 1985 5.2L-2V Light Duty Trucks All Models With "50 States" Emissions Packages Consisting of: 1 - Carburetor PN 4306453 1 - EGR Valve PN 4094891 1 - EGR Valve Gasket PN 4287938 1 - Carburetor Gasket PN 4095970 INSTRUCTIONS Using procedures as outlined in the appropriate service manual, perform the following: - Remove existing carburetor. - Install replacement carburetor PN 4306453 and gasket. - Remove EGR valve and scrape off old gasket material. - Install replacement EGR valve PN 4094891 and new gasket PN 4287938. - Start engine and check for leaks. - Check and reset if necessary, curb idle, fast idle to VECI label specifications. - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 651 1985 5.2L-2V Light Duty Trucks All Models With Federal Emissions Package (49 States) Consisting of: 2 - Main Metering Jet #147 PN 4271983 1 - EGR Valve PN 4287678 1 - EGR Valve Gasket PN 4287938 1 - Carburetor Base Gasket PN 4095970 INSTRUCTIONS Per instructions in appropriate service manual, perform the following: - Remove carburetor from engine. - Remove air horn from carburetor. FIGURE 11 - Holley 2280 Main Metering Jets - Remove existing main metering jet (Figure 11). - Install main metering jets provided, PN 4271983. - Adjust vacuum kick to 0.150". - Adjust mechanical unloader to 0.280". - Remove EGR valve and scrape off old gasket material. - Install new EGR valve PN 4287678 with new gasket PN 4287938. - Start engine, check for leaks. - Prepare carburetor for propane idle set and reinstall on engine using gasket PN 4095970. - Start engine and check for leaks. - Perform propane idle adjustment to 700 rpm (curb idle) and 770 rpm (propane enriched idle). - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. 5.9L-4V Light Duty Trucks All Automatic Models With Federal Emissions Package Consisting of: 1 - Carburetor PN 4342807 1 - EGR Valve PN 4287659 1 - Carburetor Base Gasket PN 3698365 1 - EGR Valve Gasket PN 4287938 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 652 INSTRUCTIONS - Remove existing carburetor. - Install new carburetor PN 4342807 along with new carburetor base gasket PN 3698365. - Raise the rear wheels of the vehicle with the transmission in neutral. Rotate the rear wheels through one revolution and determine the axle ratio. - If the vehicle has a 3.55 or 4.10 axle, replace EGR valve with PN 4287659 and gasket PN 4287938. - Start engine and check for leaks. - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. 5.9L-4V Light Duty Trucks All Manual Models With Federal Emission Package Consisting of: 1 - Carburetor PN 4342807 1 - Carburetor Base Gasket PN 3698365 INSTRUCTIONS - Remove original carburetor. - Install replacement carburetor PN 4342807 using new base gasket PN 3698365. - Start engine and check for leaks. - Type in changes made on Emission Update Label PN 4275084 and affix to engine compartment next to original VECI label. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 653 Air/Fuel Mixture: Technical Service Bulletins Propane Idle Adjustment - Determination Guidelines Models 1985 Model Year Vehicles Subject Guidelines For Determining the Use of Idle Mixture Adjustment Index FUEL Date 10/1/84 No.. 14-46-84 P-4283C This bulletin should serve as a guideline to help determine when a propane or "CO" method idle set is to be performed. The propane or "CO" method idle mixture adjustment should only be performed if it is determined necessary by the propane or "CO" method idle check in the respective year Driveability Test Procedure books or service manual. More specifically, propane or "CO" method idle mixture adjustment should only be used if an idle "problem" still exists after normal diagnosis has revealed no other faulty condition such as incorrect idle speed, incorrect basic ignition timing, faulty hose, or wire connections, etc. It is also important to make sure the EFC/ESA combustion computer system is operating properly. Adjustment of the idle mixture should also be performed after a major carburetor overhaul. A guideline of conditions for determining whether a propane or "CO" method idle set is needed is attached. The conditions listed below are affected by idle mixture adjustment: ^ Rough Idle Warm ^ Breakaway Sag-Light Throttle Tip In ^ Decel Die Out ^ After a Major Carburetor Overhaul The conditions listed below are not affected by idle mixture adjustment: ^ Spark Knock ^ Poor Fuel Economy ^ Road Load Surge ^ Decel Bucking ^ Long Cold Crank ^ Cold Start Die Out Time ^ After-Run (dieseling) ^ Lack of Power on ^ Cold Rough Idle Acceleration POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Adjustments > Idle Mixture and Speed Adjustments Air/Fuel Mixture: Adjustments Idle Mixture and Speed Adjustments 1981-86: Disconnect and plug canister control and EGR vacuum hoses. Remove PCV valve from grommet and allow it to draw underhood air. With ESC, ground carb switch and disconnect Oxygen sensor. 1981-82: Set idle speed screw to specification. Set cam to specified step. Set fast idle. 1983-88, 6 & 8 cyl. models with solenoids.: Turn A/C on, set blower to low, disconnect compressor clutch wire. Without A/C, apply battery voltage to solenoid. Adjust speed-up solenoid by removing adjusting screw and spring and inserting a one-eighth inch allen wrench into socket and turning. Set idle speed by adjusting screw on carb body. 1987-88 4cyl.: Energize radiator fan with a jumper wire. Remove PCV valve from grommet and disconnect vacuum kicker solenoid electrical lead. Disconnect oxygen sensor test connector on left fender shield. Adjust idle speed screw on top of solenoid to specified idle speed. Place fast idle cam on specified step and adjust to specified value. Disconnect idle solenoid electrical lead and set base idle to specified value. Other models: Set idle speed by turning screw on carb body. Set cam to specified step and adjust fast idle to specification. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Adjustments > Idle Mixture and Speed Adjustments > Page 656 Air/Fuel Mixture: Adjustments Idle Mixture (Propane Method) Fig. 1 Propane enrichment specification chart 1985 HOLLEY 6280 CARBURETOR This procedure should only be used after normal diagnosis has revealed no other faults, or if carburetor has been overhauled. Idle mixture adjustment requires artificial propane enrichment. A propane enrichment tool, C-4464 or equivalent, must be used to adjust idle mixture. Before proceeding, make sure that propane cylinder is adequately filled to ensure correct propane flow. 1. Remove concealment plug cap from mixture adjusting screw. Refer to appropriate carburetor section. 2. Set parking brake and place transmission in Neutral position. 3. Turn off all lights and accessories, then connect tachometer. 4. Start engine and allow to reach normal operating temperature, then turn off engine. 5. Disconnect and plug the vacuum hose at the EGR valve and ESA computer. 6. Disconnect and plug canister purge hose at canister. 7. Disconnect carburetor ground switch and ensure switch is not grounded. 8. Disconnect and ground oxygen sensor electrical connector. 9. start engine and allow to run for at least four minutes. 10. Disconnect vacuum supply hose from choke diaphragm at the carburetor, then install propane hose in its place. 11. Remove PCV valve from cylinder head and allow to draw in underhood air. Ensure that propane cylinder remains upright during procedure. 12. Open main propane valve fully. Slowly open propane metering valve until maximum idle RPM is obtained. Too much propane will cause engine speed to drop. Adjust metering valve to obtain maximum idle RPM. 13. With propane flowing, adjust idle speed to specified enriched RPM, Fig. 1, by turning idle speed screw. 14. Adjust metering valve to obtain maximum RPM. If there has been a change in maximum RPM, readjust idle speed screw to specified enriched RPM. 15. Turn off main propane valve and allow engine speed to stabilize. 16. Adjust mixture screws to obtain smoothest idle at specified curb idle RPM, allowing time between adjustments for engine speed to stabilize. 17. Turn on main propane valve and adjust metering valve to obtain maximum engine RPM. If maximum engine speed differs by more than 25 RPM from specified enriched RPM, repeat steps 12 through 17. 18. When adjustment is correct, turn off both propane valves, stop engine and remove tool. 19. Install new concealment plug, then connect oxygen sensor electrical connector. 20. Connect vacuum line at ESA, then perform ``Curb Idle Speed, Adjust'' and ``Fast Idle Speed, Adjust'' procedures. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package Technical Service Bulletin # 250485 Date: 850506 High Altitude Conversion Package Models 1985 Light Duty Domestic Trucks Subject High Altitude Conversion Packages & Adjustment for Improved Engine Performance Index EMISSIONS Date May 6, 1985 No.. 25-04-85 P-1522-C Packages are now available to accommodate a customer who wishes to convert his 1985 low altitude vehicle for improved high altitude (over 4,000 feet above sea level) engine performance. Vehicles with the low altitude package transferred to service in high altitude areas may exhibit undesirable driveability. However, the installation of a high altitude conversion package is voluntary and at the customer's expense. The high altitude field conversion packages and procedures outlined below have been authorized on the following 1985 non-altitude equipped engine families in service at altitudes above 4,000 feet above sea level. CONVERSION INSTRUCTIONS Sea Level to Altitude FIGURE 1 - Vehicle Emission Control Information Label IMPORTANT: IN SOME OF THE CONVERSION PROCEDURES YOU WILL BE REQUIRED TO INSTALL A NEW VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL PN 4275084. THIS LABEL HAS TWO AREAS THAT ARE IMPACT IMPRINTABLE WITH A TYPEWRITER (SEE FIGURE 1). If you are required to readjust timing, curb idle speed, or fast idle speed to a specification different than the original VECI label specification, then just type in the new specification after the subject operation. If you are asked to refer to the original VECI label specifications, type in on the right hand side of the label "Refer to Original VECI Label." Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 661 In every case where this label is used, type in after - AUTHORITY OF Technical Service Bulletin #25-04-85, and your dealer code below. Label PN 4275084 is available from Parts Supply. FIGURE 2 - Vehicle Emission Control Information Label The engine family chart below will help identify the appropriate parts to be installed by recording body style and engine family from the original VECI label. This chart cross references the EPA engine family with the engine application used in the accompanying instructions (refer to Figure 2). EPA Engine Family Engine Application (Found on VECI Label) 2.2L-2V Federal FCR2.2T2AAB6 2.2L-2V 50 States FCR2.2T2HBM9 2.6L-2V Federal FCR2.6T2AAB8 3.7L-1V Federal FCR3.7T1BBA0 5.2L-2V 50 States FCR5.2T2HBN1 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 662 5.2L-2V Federal FCR5.2T2BBF6 5.9L-4V Federal FCR5.9T4BBF1 POLICY: Information only 1985 2.2L-2V Light Duty Trucks All Models With Federal Emissions Package (49 States) Dodge Ram Van, Dodge Caravan, Plymouth Voy Consisting of: 1 - #211 Primary Main Jet PN 4293797 1 - #215 Secondary Main Jet PN 4240006 1 - #180 Primary High Speed Bleed PN 4342920 1 - #210 Secondary High Speed Bleed PN 4342921 1 - Carburetor Air Horn Gasket PN 4293846 INSTRUCTIONS FIGURE 1. Holley 5220 Primary Main Metering Jet #211 FIGURE 2. Holley 5220 Secondary Main Metering Jet #223 - Remove carburetor air horn. - Remove primary and secondary main metering jets. Refer to Figures 1 and 2. - Install #211 primary main metering jet PN 4293797. - Install #215 secondary main metering jet PN 4240006. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 663 FIGURE 3. Holley 5220 Primary High Speed Bleed #180 FIGURE 4. Holley 5220 Secondary High Speed Bleed #210 - Remove primary and secondary high speed bleeds. Refer to Figures 3 and 4. - Install #180 primary high speed bleed PN 4342920. - Install #210 secondary high speed bleed PN 4342921. FIGURE 5. Holley 5220 Power Valve Location - Turn power valve (Figure 5) two full turns counterclockwise (lean). - Reinstall air horn with new air horn gasket PN 4293846. Start engine and check for leaks. - Warm up engine and set idle speed to that specified on the VECI label. - Type in changes made on Emission Update Label PN 4275084 and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 664 1985 2.2L-2V Light Duty Truck Dodge Ram Van, Dodge Caravan & Plymouth Voyager Only Equipped With "50 States" Emission Package Consisting of: 1 - Carburetor (manual or automatic PN 4342891 transmission) Also order conversion hardware package. 1 - Hardware Package PN 4342950 Consisting of: 1 - Carburetor Base Gasket PN 4095975 1 - H.A.C. PN 4306202 1 - Hose Routing Diagram NPN 1 - Mounting Bracket (H.A.C.) PN 4105199 1 - H.A.C. Hose Harness NPN 3 - Mounting Screws NPN INSTRUCTIONS - Remove carburetor per instructions in appropriate engine performance/electrical shop manual. - Install new carburetor with new base gasket. FIGURE 6 - High Altitude Compensator Mounting - Install altitude compensator with bracket (Figure 6). - Install altitude compensator vacuum hose harness, route as shown in hose routing diagram (Figure 6). - Warm up engine. - Set engine idle speed to specified VECI label specification. - Set high fast idle on Step 3 (lowest) to specification. - Double check hose routing and installation of fuel lines. - Type in changes made on the Emission Update Label PN 4275084 and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 665 1985 2.6L-2V Light Duty Truck All Models With Federal Emissions Package (49 States) Consisting of: 1 - Carburetor Jet Kit PN MD088294 containing: #110 Primary Main Jet #175 Secondary Main Jet #100 Primary Air Bleed Jet #120 Secondary Air Bleed Jet 1 - Float Chamber Cover Gasket PN MD608639 1 - Choke Cover Screw Kit PN MD606977 1 - Carburetor Flange Gasket PN MD025344 INSTRUCTIONS - Remove carburetor from engine and take off air horn per instructions in appropriate service manual. FIGURE 7 - Mikuni Jet Locations - Remove primary and secondary main jets as shown in Figure 7. - Install #110 primary main jet and #175 secondary main jet in the primary and secondary pedestals. - Reinstall air horn on carburetor using new air horn gasket PN MD608639 and choke cover screw kit PN MD606977. FIGURE 8 - Mikuni Air Bleed Jet Locations - Remove primary and secondary air bleed jets shown in Figure 8. - Prepare carburetor for propane idle set by drilling out concealment plug. - Install #120 secondary air bleed jet and #100 primary air bleed jet. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 666 - Reinstall carburetor on engine using a new carburetor flange gasket, PN MD025344. - Remove vacuum controlled orificed tank vapor valve (VCOTV) and the vacuum/line(s) to the valve. - Remove the 3/16" tank vent line from the vapor canister and replace with 24" of 3/16" tank vent line and route directly to steel tank vent tube. - Remove the manifold vacuum line from the manifold vacuum tee (originally to the VCOTV) and cap the tee. - Remove the EGR delay valve at the corresponding EGR and carburetor ports and replace with 8" of bulk 3/16" vacuum line from stock. - Start engine and warm up to operating temperature. - Set idle rpm (curb) to 850 rpm and propane enriched rpm to 950 rpm. - Set throttle kicker rpm to 1050 rpm. FIGURE 9 - Authorized Modifications Label - Type in changes made on Authorized Modification Label, PN 4275086 (Figure 9), and affix to engine compartment next to VECI label. 1985 3.7L-1V Light Duty Trucks All Models With Federal Emission Package (49 States) Consisting of: 1 - #611 Main Metering Jet PN 3837520 1 - Carburetor Air Horn Gasket PN 4267140 INSTRUCTIONS - Remove carburetor. - Remove air horn from carburetor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 667 FIGURE 10 - Main Metering Jet Location - Remove existing main metering jet (Figure 10). - Install #611 main metering jet PN 3837520. - Reinstall air horn with new air horn gasket PN 4267140. - Drill out concealment plug and prepare carburetor for propane idle set. - Per instructions in appropriate service manual, perform a propane idle set. Reset the propane/curb idle speeds to 775/750 for manuals and 800/775 for automatics. - Reset HFI to 1600 on Step 2. - Reset choke vacuum kick to 0.120". - Reset idle solenoid speed to 850 rpm (manual transmission) or 875 (automatic transmission). - Type in changes made on Emission Update Label and affix in engine compartment next to VECI label. 1985 5.2L-2V Light Duty Trucks All Models With "50 States" Emissions Packages Consisting of: 1 - Carburetor PN 4306453 1 - EGR Valve PN 4094891 1 - EGR Valve Gasket PN 4287938 1 - Carburetor Gasket PN 4095970 INSTRUCTIONS Using procedures as outlined in the appropriate service manual, perform the following: - Remove existing carburetor. - Install replacement carburetor PN 4306453 and gasket. - Remove EGR valve and scrape off old gasket material. - Install replacement EGR valve PN 4094891 and new gasket PN 4287938. - Start engine and check for leaks. - Check and reset if necessary, curb idle, fast idle to VECI label specifications. - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 668 1985 5.2L-2V Light Duty Trucks All Models With Federal Emissions Package (49 States) Consisting of: 2 - Main Metering Jet #147 PN 4271983 1 - EGR Valve PN 4287678 1 - EGR Valve Gasket PN 4287938 1 - Carburetor Base Gasket PN 4095970 INSTRUCTIONS Per instructions in appropriate service manual, perform the following: - Remove carburetor from engine. - Remove air horn from carburetor. FIGURE 11 - Holley 2280 Main Metering Jets - Remove existing main metering jet (Figure 11). - Install main metering jets provided, PN 4271983. - Adjust vacuum kick to 0.150". - Adjust mechanical unloader to 0.280". - Remove EGR valve and scrape off old gasket material. - Install new EGR valve PN 4287678 with new gasket PN 4287938. - Start engine, check for leaks. - Prepare carburetor for propane idle set and reinstall on engine using gasket PN 4095970. - Start engine and check for leaks. - Perform propane idle adjustment to 700 rpm (curb idle) and 770 rpm (propane enriched idle). - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. 5.9L-4V Light Duty Trucks All Automatic Models With Federal Emissions Package Consisting of: 1 - Carburetor PN 4342807 1 - EGR Valve PN 4287659 1 - Carburetor Base Gasket PN 3698365 1 - EGR Valve Gasket PN 4287938 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 669 INSTRUCTIONS - Remove existing carburetor. - Install new carburetor PN 4342807 along with new carburetor base gasket PN 3698365. - Raise the rear wheels of the vehicle with the transmission in neutral. Rotate the rear wheels through one revolution and determine the axle ratio. - If the vehicle has a 3.55 or 4.10 axle, replace EGR valve with PN 4287659 and gasket PN 4287938. - Start engine and check for leaks. - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. 5.9L-4V Light Duty Trucks All Manual Models With Federal Emission Package Consisting of: 1 - Carburetor PN 4342807 1 - Carburetor Base Gasket PN 3698365 INSTRUCTIONS - Remove original carburetor. - Install replacement carburetor PN 4342807 using new base gasket PN 3698365. - Start engine and check for leaks. - Type in changes made on Emission Update Label PN 4275084 and affix to engine compartment next to original VECI label. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 670 Idle Speed: Technical Service Bulletins Propane Idle Adjustment - Determination Guidelines Models 1985 Model Year Vehicles Subject Guidelines For Determining the Use of Idle Mixture Adjustment Index FUEL Date 10/1/84 No.. 14-46-84 P-4283C This bulletin should serve as a guideline to help determine when a propane or "CO" method idle set is to be performed. The propane or "CO" method idle mixture adjustment should only be performed if it is determined necessary by the propane or "CO" method idle check in the respective year Driveability Test Procedure books or service manual. More specifically, propane or "CO" method idle mixture adjustment should only be used if an idle "problem" still exists after normal diagnosis has revealed no other faulty condition such as incorrect idle speed, incorrect basic ignition timing, faulty hose, or wire connections, etc. It is also important to make sure the EFC/ESA combustion computer system is operating properly. Adjustment of the idle mixture should also be performed after a major carburetor overhaul. A guideline of conditions for determining whether a propane or "CO" method idle set is needed is attached. The conditions listed below are affected by idle mixture adjustment: ^ Rough Idle Warm ^ Breakaway Sag-Light Throttle Tip In ^ Decel Die Out ^ After a Major Carburetor Overhaul The conditions listed below are not affected by idle mixture adjustment: ^ Spark Knock ^ Poor Fuel Economy ^ Road Load Surge ^ Decel Bucking ^ Long Cold Crank ^ Cold Start Die Out Time ^ After-Run (dieseling) ^ Lack of Power on ^ Cold Rough Idle Acceleration POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 671 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Idle Mixture and Speed Adjustments Idle Speed: Adjustments Idle Mixture and Speed Adjustments 1981-86: Disconnect and plug canister control and EGR vacuum hoses. Remove PCV valve from grommet and allow it to draw underhood air. With ESC, ground carb switch and disconnect Oxygen sensor. 1981-82: Set idle speed screw to specification. Set cam to specified step. Set fast idle. 1983-88, 6 & 8 cyl. models with solenoids.: Turn A/C on, set blower to low, disconnect compressor clutch wire. Without A/C, apply battery voltage to solenoid. Adjust speed-up solenoid by removing adjusting screw and spring and inserting a one-eighth inch allen wrench into socket and turning. Set idle speed by adjusting screw on carb body. 1987-88 4cyl.: Energize radiator fan with a jumper wire. Remove PCV valve from grommet and disconnect vacuum kicker solenoid electrical lead. Disconnect oxygen sensor test connector on left fender shield. Adjust idle speed screw on top of solenoid to specified idle speed. Place fast idle cam on specified step and adjust to specified value. Disconnect idle solenoid electrical lead and set base idle to specified value. Other models: Set idle speed by turning screw on carb body. Set cam to specified step and adjust fast idle to specification. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Idle Mixture and Speed Adjustments > Page 674 Idle Speed: Adjustments Idle Speed Adjustment Curb Idle Speed Adjustment 1. Disconnect and plug vacuum hose at EGR valve, ESA module, distributor or carburetor, as required. 2. On models equipped with carburetor ground switch, connect jumper wire between switch and ground. 3. On models not equipped with Spark Control Computer (SCC), disconnect and plug vacuum hose from carburetor at heated air temperature sensor and Orifice Spark Advance Control (OSAC) valve, if equipped. 4. On all models, disconnect and plug control hose at canister. 5. Remove PCV valve from cylinder head cover and allow to draw underhood air. 6. Connect tachometer, then start engine and allow to reach normal operating temperature. 7. On models less 1985 6280 carburetor, adjust Solenoid Idle Stop (SIS), if equipped, as follows: a. On 1983-84 models with A/C, turn on A/C and set blower on low, then disconnect A/C clutch wire. b. On 1983-84 models less A/C and all 1985-87 models, connect jumper wire between battery positive terminal and the SIS lead wire. Ensure correct jumper wire installation. Applying battery voltage to other than correct wire will damage the wiring harness. c. On all models, open throttle slightly to allow solenoid plunger to extend. d. On Holley models, remove adjusting screw and spring from solenoid, then insert 1/8 inch Allen wrench into the solenoid and adjust to correct engine RPM. e. On Carter models, turn adjusting screw on throttle lever to obtain correct engine RPM. f. On Rochester models, turn solenoid plunger screw to obtain correct engine RPM. g. Turn off A/C and reconnect clutch wire or remove jumper, if equipped. h. Install solenoid screw and spring, if equipped with Holley carburetor. 8. On models with 1985 6280 carburetor, adjust Solenoid Idle Stop (SIS) as follows: a. Disconnect and ground engine harness electrical connector from oxygen sensor. b. Allow engine to run at least five minutes, then connect a jumper wire between the battery positive terminal and SIS lead wire. Ensure correct jumper wire installation. Applying battery voltage to other than correct wire will damage the wiring harness. c. Open throttle slightly to allow solenoid plunger to extend. d. Remove adjusting screw and spring from solenoid, then insert a 1/8 inch allen wrench into the solenoid and adjust to correct engine RPM. e. Install screw and spring, then turn in screw until it bottoms out. 9. On 1983-84 models equipped with oxygen sensor feedback carburetors, proceed as follows: a. Disconnect electrical connector from oxygen sensor and ground connector. b. Remove and plug vacuum hose at vacuum transducer on SCC, then install suitable vacuum pump to vacuum transducer and apply 16 inches of vacuum. c. Allow engine to run for two minutes. If idle is not as specified, turn adjusting screw on solenoid to obtain correct RPM. 10. On 1983-84 models not equipped with oxygen sensor feedback carburetors and all 1985-87 model carburetors, proceed as follows: a. Allow engine to run for one minute. b. If idle RPM is not as specified, turn idle speed screw to obtain correct RPM. 11. On all models, turn off engine, connect vacuum lines and remove tachometer. Remove jumper wire and connect oxygen sensor electrical connector, if equipped. After step 11 has been completed, idle speed may change slightly. This condition is normal and engine speed should not be readjusted. Fast Idle Adjustment 1. Disconnect and plug vacuum hose at EGR valve, ESA computer and distributor, if equipped. 2. On models equipped with carburetor ground switch, connect jumper wire between switch and ground. 3. On models not equipped with Spark Control Computer (SCC), disconnect and plug vacuum hose from carburetor at heated air temperature sensor. 4. On all models, disconnect and plug control hose at canister. 5. Remove PCV valve from cylinder head cover and allow to draw underhood air. 6. Connect tachometer, then start engine and allow to reach normal operating temperature. 7. On models equipped with oxygen sensor feedback, disconnect electrical connector from oxygen sensor and ground connector, then allow engine to run for two minutes. 8. On models not equipped with oxygen sensor feedback, allow engine to run for one minute. 9. On all models, open throttle slightly and position fast idle adjusting screw on second highest step of fast idle cam. 10. Open choke fully, then adjust fast idle speed screw to obtain specified RPM. 11. Return to idle, then reposition adjusting screw on second highest step of fast idle cam to ensure correct RPM. Readjust if necessary. 12. Turn off engine, then connect vacuum hoses and remove tachometer. Remove jumper wire and connect oxygen sensor electrical connector, if equipped. After step 12 has been completed, idle speed may change slightly. This condition is normal and engine speed should not be readjusted. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 683 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 684 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 685 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 686 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 687 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 688 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 689 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 690 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 691 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 692 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 693 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 694 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 695 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 696 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 697 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 703 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 704 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 705 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 706 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 707 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 708 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 709 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 710 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 711 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 712 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 713 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 714 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 715 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 716 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 717 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Timing Marks and Indicators: Diagrams TIMING MARK 1981-85 5.2L & 5.9L Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams > Page 728 TIMING MARK 1981-90 Some 5.2L & 5.9L Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair Ignition Cable: Service and Repair REMOVAL AND INSTALLATION Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (1/2 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. Engine Firing Order Install cables into the proper engine cylinder firing order. When replacing the spark plug and coil cables, route the cables correctly and secure in the proper retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also cause cross ignition of the plugs or short circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made between the plug cable and the distributor cap tower. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Vacuum Advance Unit <--> [Distributor Advance Unit] > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Vacuum Advance Unit <--> [Distributor Advance Unit] > Component Information > Specifications > Page 736 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Vacuum Control > Component Information > Locations Distributor Vacuum Control: Locations Orifice Spark Advance Control (OSAC) Valve Location. In Air Cleaner Housing Applicable to: V8 Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Check Specifications Compression Check Specifications Compression Pressure 100 psi At cranking speed, engine temperature normalized, throttle Note: Minimum open Maximum Variation 25 psi Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments 1981-87 6-225 (3.7L) & ALL 1980-87 V8 ENGINES These engines are equipped with hydraulic lifters. No provision for adjustment is provided. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications Drive Belt: Specifications A belt in operation for 15 minutes is considered a used belt. Strand Tension method: Use gauge. Measurements are in pounds. Used belts, 70; New belts, 120. Deflection method: One-fourth to one-half of a inch or 6-12 millimeters with 10 lbs. of force applied at midpoint of belt. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 761 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 762 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 763 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 764 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 765 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 766 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 767 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 768 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 769 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 770 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 771 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 772 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 773 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 774 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 775 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 781 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 782 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 783 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 784 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 785 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 786 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 787 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 788 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 789 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 790 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 791 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 792 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 793 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 794 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 795 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts Technical Service Bulletin # 181986 Date: 860210 Choke - Hard Hot Restarts Models All 1985-1986 Cars & Trucks Equipped With Quadrajet 4-BBL Carburetors (318-360) Subject Premature Choke Closing Causing Hard Hot Restarts Index DRIVEABILITY Date February 10, 1986 No. 18-19-86 P-362-C Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Partial choke closure which results in a rich condition causing hard worm and hard hot starts in cool or cold ambients. The vehicle may exhibit block smoke out the tailpipe for the first few miles of driving. DIAGNOSIS Remove the air cleaner and visually verify the choke blade is closing when the engine is worm or hot while the ambient is cool or cold. PARTS REQUIRED For 318 4BBL Passenger Cars and 318/360 4BBL D and W Trucks Driveability PN 4397683 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose (Preformed) PN 4361146 1 Heater Hose PN 3849197 1 Screw PN 3730000 "M" body cars will require the following to be ordered separately: 1 Water Valve PN 4085474 3 Tie Wraps PN 6015756 For 318 4BBL Police Vehicles With Silicone Hoses Only Driveability Package PN 4397684 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose (Preformed Silicone) PN 3849564 1 Heater Hose Silicone PN 3849472 1 Water Valve PN 4085474 1 Screw PN 3730000 3 Tie Wraps PN 6015756 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 805 For 318 4BBL/360 4BBL "B" Model Vans Driveability Package PN 4397685 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose PN 4361142 3 Tie Wraps PN 6015756 1 Screw PN 3730000 To be ordered separately for all vehicles: 1 Authorized Modification Label PN 4275086 Repair Procedures This repair procedure involves the routing of the heater supply hose so it contacts the choke housing. The heat from this hose reduces the tendency of the choke to close before the engine cools off. It is, therefore, very important the heater hose be in direct contact with the choke housing. "M" Body Passenger Cars and D-W Series Trucks Without Silicone Heater Hoses and With Air Conditioning 1. Remove and discard the supply heater hoses and the water control valve. This is the hose that connects the intake manifold to the heater core. 2. Remove the return heater hose from the heater core at the cowl and install it on the opposite nipple of the heater core. 3. Remove and discard 33 inches off the straight end of the preformed hose, PN 4361146. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 806 FIGURE 2 4. Clamp water valve, PN 4085474, onto the straight end of heater hose, PN 4361146, which was cut off in Step 3 above. This water valve has an embossed arrow on it to indicate water flow. This arrow must point toward the heater core or precise control of water flow to the heater will be impossible. Proper orientation of this valve is illustrated in Figure 2. Install heater hose, PN 3849197, on the other side of the water valve. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 807 FIGURE 1 5. Attach supply heater hose bracket, PN 4307576, to the intake manifold boss using enclosed screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 808 FIGURE 3 6. Install the 90~ bend of the supply heater hose and valve assembly onto the nipple on intake manifold. Route the supply hose past the carburetor choke housing and install the straight end of the hose onto the heater core inlet nipple. Install heater hose onto bracket and clamp securely in place (see Figure 3). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 809 FIGURE 6 7. Attach Authorization Modification Label, PN 4275086, as illustrated in Figure 6. "M" Body Police With Silicone Heater Hoses 1. Follow the same installation procedure as on "M" body passenger car except silicone heater hose, PN 3849564, must be substituted for passenger car hose, PN 4361146. Silicone heater hose, PN 3849472, must be substituted for passenger car heater hose, PN 3849197. FIGURE 6 2. Attach Authorization Modification Label, PN 4274086, as illustrated in Figure 6. D and W Model Trucks Without Air Conditioning 1. Remove and discard the supply heater hose that connects the intake manifold to the heater core. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 810 FIGURE 1 2. Attach heater hose bracket to intake manifold boss using screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 811 FIGURE 5 3. Install 90~ bend of heater supply hose, PN 4361146, onto the intake manifold nipple. Route this hose post carburetor choke housing and install straight end of hose on the heater core nipple. Install hose into bracket and clump hose securely in place (see Figure 5). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 812 FIGURE 6 4. Attach Authorization Modification Label, PN 4274086, as illustrated in Figure 6. "B" Model Van With and Without Air Conditioning 1. Remove and discard supply heater hose that connects the intake manifold to the heater core or to the water valve, if the vehicle is air conditioning equipped. FIGURE 1 2. Attach heater hose bracket, PN 4307576, to intake manifold boss using screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 813 3. Install 90~ end of supply heater hose, PN 4361142, onto the intake manifold nipple. Route this heater supply hose post the carburetor choke housing and install the straight end on the heater core or on the water valve, if the vehicle has air conditioning. This hose must be cut to length as required. Install this heater supply hose into the hose bracket previously attached to the intake manifold. FIGURE 4 4. Using tie wraps, PN 6015756, secure supply heater hose to automatic transmission dip stick tube. Use caution as not to deform dip stick tube, as this will make transmission fluid level checks difficult or impossible. Using tie wraps, tie the supply and return heater hoses together as illustrated in Figure 4. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 814 FIGURE 6 5. Attach Authorization Modification Label, PN 4275086, as illustrated in Figure 6. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 14-30-56-96 Premature Choke Closing "B" Van 0.7 Hrs. D-W Truck and "M" Body Passenger Car 0.5 Hrs. 14-30-56-97 Optional Equipment Air Conditioning "B" Van 0.3 Hrs. D-W Truck and "M" Body Passenger Car 0.4 Hrs. FAILURE CODE: AM - Authorized Modification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 815 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts Technical Service Bulletin # 181986 Date: 860210 Choke - Hard Hot Restarts Models All 1985-1986 Cars & Trucks Equipped With Quadrajet 4-BBL Carburetors (318-360) Subject Premature Choke Closing Causing Hard Hot Restarts Index DRIVEABILITY Date February 10, 1986 No. 18-19-86 P-362-C Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Partial choke closure which results in a rich condition causing hard worm and hard hot starts in cool or cold ambients. The vehicle may exhibit block smoke out the tailpipe for the first few miles of driving. DIAGNOSIS Remove the air cleaner and visually verify the choke blade is closing when the engine is worm or hot while the ambient is cool or cold. PARTS REQUIRED For 318 4BBL Passenger Cars and 318/360 4BBL D and W Trucks Driveability PN 4397683 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose (Preformed) PN 4361146 1 Heater Hose PN 3849197 1 Screw PN 3730000 "M" body cars will require the following to be ordered separately: 1 Water Valve PN 4085474 3 Tie Wraps PN 6015756 For 318 4BBL Police Vehicles With Silicone Hoses Only Driveability Package PN 4397684 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose (Preformed Silicone) PN 3849564 1 Heater Hose Silicone PN 3849472 1 Water Valve PN 4085474 1 Screw PN 3730000 3 Tie Wraps PN 6015756 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 821 For 318 4BBL/360 4BBL "B" Model Vans Driveability Package PN 4397685 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose PN 4361142 3 Tie Wraps PN 6015756 1 Screw PN 3730000 To be ordered separately for all vehicles: 1 Authorized Modification Label PN 4275086 Repair Procedures This repair procedure involves the routing of the heater supply hose so it contacts the choke housing. The heat from this hose reduces the tendency of the choke to close before the engine cools off. It is, therefore, very important the heater hose be in direct contact with the choke housing. "M" Body Passenger Cars and D-W Series Trucks Without Silicone Heater Hoses and With Air Conditioning 1. Remove and discard the supply heater hoses and the water control valve. This is the hose that connects the intake manifold to the heater core. 2. Remove the return heater hose from the heater core at the cowl and install it on the opposite nipple of the heater core. 3. Remove and discard 33 inches off the straight end of the preformed hose, PN 4361146. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 822 FIGURE 2 4. Clamp water valve, PN 4085474, onto the straight end of heater hose, PN 4361146, which was cut off in Step 3 above. This water valve has an embossed arrow on it to indicate water flow. This arrow must point toward the heater core or precise control of water flow to the heater will be impossible. Proper orientation of this valve is illustrated in Figure 2. Install heater hose, PN 3849197, on the other side of the water valve. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 823 FIGURE 1 5. Attach supply heater hose bracket, PN 4307576, to the intake manifold boss using enclosed screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 824 FIGURE 3 6. Install the 90~ bend of the supply heater hose and valve assembly onto the nipple on intake manifold. Route the supply hose past the carburetor choke housing and install the straight end of the hose onto the heater core inlet nipple. Install heater hose onto bracket and clamp securely in place (see Figure 3). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 825 FIGURE 6 7. Attach Authorization Modification Label, PN 4275086, as illustrated in Figure 6. "M" Body Police With Silicone Heater Hoses 1. Follow the same installation procedure as on "M" body passenger car except silicone heater hose, PN 3849564, must be substituted for passenger car hose, PN 4361146. Silicone heater hose, PN 3849472, must be substituted for passenger car heater hose, PN 3849197. FIGURE 6 2. Attach Authorization Modification Label, PN 4274086, as illustrated in Figure 6. D and W Model Trucks Without Air Conditioning 1. Remove and discard the supply heater hose that connects the intake manifold to the heater core. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 826 FIGURE 1 2. Attach heater hose bracket to intake manifold boss using screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 827 FIGURE 5 3. Install 90~ bend of heater supply hose, PN 4361146, onto the intake manifold nipple. Route this hose post carburetor choke housing and install straight end of hose on the heater core nipple. Install hose into bracket and clump hose securely in place (see Figure 5). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 828 FIGURE 6 4. Attach Authorization Modification Label, PN 4274086, as illustrated in Figure 6. "B" Model Van With and Without Air Conditioning 1. Remove and discard supply heater hose that connects the intake manifold to the heater core or to the water valve, if the vehicle is air conditioning equipped. FIGURE 1 2. Attach heater hose bracket, PN 4307576, to intake manifold boss using screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 829 3. Install 90~ end of supply heater hose, PN 4361142, onto the intake manifold nipple. Route this heater supply hose post the carburetor choke housing and install the straight end on the heater core or on the water valve, if the vehicle has air conditioning. This hose must be cut to length as required. Install this heater supply hose into the hose bracket previously attached to the intake manifold. FIGURE 4 4. Using tie wraps, PN 6015756, secure supply heater hose to automatic transmission dip stick tube. Use caution as not to deform dip stick tube, as this will make transmission fluid level checks difficult or impossible. Using tie wraps, tie the supply and return heater hoses together as illustrated in Figure 4. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 830 FIGURE 6 5. Attach Authorization Modification Label, PN 4275086, as illustrated in Figure 6. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 14-30-56-96 Premature Choke Closing "B" Van 0.7 Hrs. D-W Truck and "M" Body Passenger Car 0.5 Hrs. 14-30-56-97 Optional Equipment Air Conditioning "B" Van 0.3 Hrs. D-W Truck and "M" Body Passenger Car 0.4 Hrs. FAILURE CODE: AM - Authorized Modification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 831 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Testing and Inspection Brake Fluid: Testing and Inspection NOTE: Swollen rubber parts indicate the presence of petroleum in the brake fluid. To confirm that contamination exists, make the following test: Place a small amount of the drained brake fluid into a small clear glass bottle. Separation of the fluid into distinct layers will indicate mineral oil content. If there is any question of mineral oil content, drain system, flush thoroughly and replace all rubber parts. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Testing and Inspection > Page 836 Brake Fluid: Service and Repair Aluminum Master Cylinder NOTES: - With disc brakes, fluid level can be expected to fall as the brake pads wear. - Check master cylinder fluid level twice annually. - Master cylinder reservoirs are marked with the words "fill to bottom of rings". 1. Wipe caps and reservoir clean to prevent dirt and foreign matter from dropping into the reservoir. 2. Remove the caps to check the level. - On aluminum master cylinder add DOT 3 fluid to bring the level to the bottom of the primary split ring. - On the cast iron master cylinder, add DOT 3 fluid to bring the level to within a 1/4 inch of the top of reservoir. CAUTION: Use fluid other than DOT 3 that may have a lower boiling point -- such as fluid identified as 7OR1 or unidentified as to specification -- could result in brake failure during long, hard braking. CAUTION: Do not use fluid which has been stored in an unsealed container. Brake fluid stored in this manner will absorb moisture which could result in brake failure during long, hard braking. CAUTION: Use of petroleum based fluids will result in seal damage. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Recycling Recommendations Coolant: Technical Service Bulletins Engine Coolant - Recycling Recommendations SUBJECT: Engine Coolant Recycling NO.: 07-03-90 GROUP: COOLING DATE: Dec. 21, 1990 MODELS: All Domestic & Import Vehicles DISCUSSION: A number of systems are being marketed to "recycle" or "reconstitute" used ethylene glycol antifreeze/coolant in the dealership. Some of the systems have been advertised as producing a recycled antifreeze "as good as" original and suggest the recycled product is suitable for use in Chrysler Corporation vehicles. Tests, so far, indicate most of these systems merely remove suspended solids from the used antifreeze/coolant through the use of various size filters. These systems do not remove glycol degradation products, or dissolved solids, which can cause water pump seal wear. These systems use a universal "reinhibitor package". The "reinhibitor package" can not restore every type antifreeze/coolant inhibitor system to a like new condition. Tests results indicate these "recycled" products do not consistently provide the protection required in Chrysler Corporation engines and cooling systems. The use of these "reconstituted" antifreeze/coolants is not authorized in the performance of any repair covered under the provisions of the warranty. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Page 841 Coolant: Specifications MAKE, YEAR & MODEL LITERS QUARTS D, W Series Pickups 1993-91 3.9L V-6 14.0 15.1 5.2L V-8 16.0 17.0 5.9L V-8 Gas 14.7 15.5 5.9L I-6 Diesel: AT 16.1 17.0 MT 15.1 16.0 1990-88 3.9L V-6 14.0 15.1 5.2L V-8 16.0 17.0 5.9L V-8 Gas 14.5 15.5 5.9L I-6 Diesel: AT 15.7 16.5 MT 14.7 15.5 1987-83 3.7L I-6 11.5, 12.5* 12.0, 13.0* 5.2L V-8 15.0, 16.0* 16.0, 17.0* 5.9L V-8 13.5, 14.5* 14.5, 15.5* * Indicates with air conditioning Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Automatic Transmission - New Fluid Type Fluid - A/T: Technical Service Bulletins Automatic Transmission - New Fluid Type Models All 1978-1985 Equipped With Automatic Transmission & Lock-Up Torque Converter Subject New Automatic Transmission Fluid Index TRANSMISSION Date June 17, 1985 No. 21-04-85 P-2131 A new automatic transmission fluid Type 7176, (PN 4318077 - quart and 4318079 - 55 gallon) has been released for all vehicles equipped with automatic transmission and lock-up torque converter. Aftermarket fluids can vary in terms of their friction characteristics and this in turn can affect the performance of the lock-up clutch, causing shudder and/or excessive slippage. Use of the new fluid will help to insure that the lock-up clutch will perform satisfactorily after the fluid has been replaced. Type 7176 fluid should be used any time it is necessary to replace the fluid in a lock-up torque converter equipped transmission. If a lock-up shudder condition is encountered, check all linkage adjustments and drain and refill the transmission with Type 7176 fluid prior to attempting any other repairs, especially if the fluid has been changed previously. POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Transaxle/Transmission - Automatic Fluid - A/T: Specifications Transaxle/Transmission - Automatic TYPE.................................................................................................................................................... ......................................................................AF‡, AP CAPACITY, Initial Refill*: All models................ .............................................................................................................................................................. ...........3.8 Liters 4.0 Quarts *With engine at operating temperature, shift transmission through all gears. Check fluid level in NEUTRAL and add fluid as needed ‡1986 and later may use AF only when AP is not available Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Transaxle/Transmission - Automatic > Page 848 Fluid - A/T: Specifications Initial Refill Capacity TYPE.................................................................................................................................................... ......................................................................AF‡, AP CAPACITY, Initial Refill*: All models................ .............................................................................................................................................................. ...........3.8 Liters 4.0 Quarts *With engine at operating temperature, shift transmission through all gears. Check fluid level in NEUTRAL and add fluid as needed ‡1986 and later may use AF only when AP is not available Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications Fluid - M/T: Specifications A833 OD............................................................................................................................................... .......................................................................AF, AP 75W, 75W-80, 80W-90, 85W-90, 90 GL-5may be used NP435........................................................... .................................................................................................................................GL-5, SF/CC, SF/CD, SG SF/CC, SF/CD, SG: Above 32°F (0°C), 50; below 32°F (0°C), 30 GL-5: Above 90°F (32°C), 140; above -10°F (-23°C), 90; below -10°F (-23°C), 80W NP2500 ......................................... .............................................................................................................................................10W-30 SF/CC, SF/CD, SG CAPACITY, Refill: NP435..................................................................................... ...............................................................................................................3.3 Liters 7.0 Pints NP2500................................................................................................................................................. .................................................1.9 Liters 4.0 Pints A833 OD............................................................................................................................................... ................................................3.5 Liters 7.5 Pints Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Customer Interest for Fluid - Differential: > 211587 > Aug > 87 > Transfer Case - High Effort Shifting From 2-H to 4-H Fluid - Differential: Customer Interest Transfer Case - High Effort Shifting From 2-H to 4-H Models 1985-1987 "W" & "AW" Trucks With NP208 Transfer Case & "N" Body 4 x 4 With NP207 Transfer Case Subject High Shift Effort When Shifting From 2-High to 4-High Index TRANSMISSION Date August 17, 1987 No.. 21-15-87 (C10-21) P-2869 SYMPTOM/CONDITION High shift effort or total block out while shifting into 4-High (four-wheel drive transfer case). Condition occurs during cold weather operation while shifting the transfer case into 4-High from the 2-High mode. DIAGNOSIS With vehicle cold (below +30~F), shift transfer case from 2-High into 4-High with the vehicle stationary. It may be necessary to move vehicle slightly forward or rearward to engage front axle. If the transfer case does not shift with the vehicle stationary, check external shift linkage for proper adjustment (see appropriate service manual for transfer case shift linkage adjustment procedure). With vehicle still cold, attempt to shift from 2-High to 4-High at approximately 25 mph. While shifting, apply a constant force to the transfer case shift lever, not a quick pull. This will allow the synchronizer time to get the front propshaft up to speed. With cold front axle lubricant, the vehicle may require high effort for an extended time, or will not shift. Warm front axle lubricant by operating vehicle in 4-High mode for approximately 10 miles. Shift transfer case from 2-High to 4-High several times. Allow time between shifts to insure synchronizer is out of the 4-High mode before shifting. If vehicle exhibits high shifting effort in cold weather operation (below +30~F), but has reasonable effort and consistency after vehicle is warm, perform the front axle lubricant fill procedure as outlined later in this bulletin. If vehicle requires high shifting effort and shifts inconsistently after the front axle lubricant is warm, the following transfer case parts might require replacement, in addition to the front axle lubricant change. PARTS REQUIRED Transfer Case - NP208 ("W" and "AW" Truck) 1 Synchronizer Assembly PN 4329516 1 Drive Sprocket Assembly PN 4329527 Transfer Case - NP207 (N5 Dakota 4 x 4) 1 Synchronizer Assembly PN 4446457 1 Drive Sprocket Assembly PN 4446453 Front Axle Mopar High Performance Synthetic PN 4467707 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Customer Interest for Fluid - Differential: > 211587 > Aug > 87 > Transfer Case - High Effort Shifting From 2-H to 4-H > Page 860 Axle Lube (1 quart can) REPAIR PROCEDURES This procedure involves replacing the synchronizer assembly and axle lube. Transfer Case See appropriate service manual for replacement procedures. Front Axle 1. Using a suction pump, remove as much of the axle lubricant as possible. NOTE: IT IS NOT NECESSARY TO REMOVE THE DIFFERENTIAL COVER. 2. Refill the axle with Mopar High Performance Synthetic Axle Lube, PN 4467707, as specified below. "W" and "AW" Truck: Fill to within 1/4" of the bottom of the fill plug hole (approximately 84 ounces). N5 Dakota 4 x 4: Fill to 1/2" below the bottom of the fill plug hole (approximately 40 ounces). NOTE: OVERFILL CAN RESULT IN LUBRICANT "FOAMING" AND/OR UNIT OVERHEATING. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Refer to Labor Operation Time Schedule for operation and time Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - Differential: > 211587 > Aug > 87 > Transfer Case - High Effort Shifting From 2-H to 4-H Fluid - Differential: All Technical Service Bulletins Transfer Case - High Effort Shifting From 2-H to 4-H Models 1985-1987 "W" & "AW" Trucks With NP208 Transfer Case & "N" Body 4 x 4 With NP207 Transfer Case Subject High Shift Effort When Shifting From 2-High to 4-High Index TRANSMISSION Date August 17, 1987 No.. 21-15-87 (C10-21) P-2869 SYMPTOM/CONDITION High shift effort or total block out while shifting into 4-High (four-wheel drive transfer case). Condition occurs during cold weather operation while shifting the transfer case into 4-High from the 2-High mode. DIAGNOSIS With vehicle cold (below +30~F), shift transfer case from 2-High into 4-High with the vehicle stationary. It may be necessary to move vehicle slightly forward or rearward to engage front axle. If the transfer case does not shift with the vehicle stationary, check external shift linkage for proper adjustment (see appropriate service manual for transfer case shift linkage adjustment procedure). With vehicle still cold, attempt to shift from 2-High to 4-High at approximately 25 mph. While shifting, apply a constant force to the transfer case shift lever, not a quick pull. This will allow the synchronizer time to get the front propshaft up to speed. With cold front axle lubricant, the vehicle may require high effort for an extended time, or will not shift. Warm front axle lubricant by operating vehicle in 4-High mode for approximately 10 miles. Shift transfer case from 2-High to 4-High several times. Allow time between shifts to insure synchronizer is out of the 4-High mode before shifting. If vehicle exhibits high shifting effort in cold weather operation (below +30~F), but has reasonable effort and consistency after vehicle is warm, perform the front axle lubricant fill procedure as outlined later in this bulletin. If vehicle requires high shifting effort and shifts inconsistently after the front axle lubricant is warm, the following transfer case parts might require replacement, in addition to the front axle lubricant change. PARTS REQUIRED Transfer Case - NP208 ("W" and "AW" Truck) 1 Synchronizer Assembly PN 4329516 1 Drive Sprocket Assembly PN 4329527 Transfer Case - NP207 (N5 Dakota 4 x 4) 1 Synchronizer Assembly PN 4446457 1 Drive Sprocket Assembly PN 4446453 Front Axle Mopar High Performance Synthetic PN 4467707 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - Differential: > 211587 > Aug > 87 > Transfer Case - High Effort Shifting From 2-H to 4-H > Page 866 Axle Lube (1 quart can) REPAIR PROCEDURES This procedure involves replacing the synchronizer assembly and axle lube. Transfer Case See appropriate service manual for replacement procedures. Front Axle 1. Using a suction pump, remove as much of the axle lubricant as possible. NOTE: IT IS NOT NECESSARY TO REMOVE THE DIFFERENTIAL COVER. 2. Refill the axle with Mopar High Performance Synthetic Axle Lube, PN 4467707, as specified below. "W" and "AW" Truck: Fill to within 1/4" of the bottom of the fill plug hole (approximately 84 ounces). N5 Dakota 4 x 4: Fill to 1/2" below the bottom of the fill plug hole (approximately 40 ounces). NOTE: OVERFILL CAN RESULT IN LUBRICANT "FOAMING" AND/OR UNIT OVERHEATING. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Refer to Labor Operation Time Schedule for operation and time Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Differentials Fluid - Differential: Specifications Differentials Above 90° (32°C), 140, 80W-140, 85W-140; above -10°F (-23°C), 90, 80W-90, 80W-140; 85W-140; below -10°F (-23°C), 75W, 80W, 75W-90, 80W-140 REAR: Standard................................................................................................................................... ..........................................................................GL-5 Anti-Spin, Limited-Slip, Powr-Loc, Sure-Grip, Trac-Loc....................................................................... ......................................................................GL-5* FRONT: 4 x 4....................................................................................................................................... .........................................................................GL-5 CAPACITY, Refill: Front: 4-wheel drive Dakota. .............................................................................................................................................................. .................................1.2 Liters 2.6 Pints Spicer 60F axle..................................................................................................................................... ..............................................3.1 Liters 6.5 Pints Others................................................................................................................................................... ..............................................2.7 Liters 5.6 Pints Rear 7 1/4" ring gear with 2 1/2" dia. axle housing adjacent to differential.........................................................................................1.2 Liters 2.5 Pints Spicer 60, 60 HD.................................................................................................................................. ..............................................2.8 Liters 6.0 Pints Spicer 70.............................................................................................................................................. ...............................................3.3 Liters 7.0 Pints Others................................................................................................................................................... ..............................................2.1 Liters 4.5 Pints ANTI-SPIN, LIMITED-SLIP, POWR-LOC, SURE-GRIP OR TRAC-LOC IDENTIFICATION Lift both rear wheels off ground, turn one wheel & other will rotate in same direction Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Differentials > Page 869 Fluid - Differential: Specifications Differential Above 90° (32°C), 140, 80W-140, 85W-140; above -10°F (-23°C), 90, 80W-90, 80W-140; 85W-140; below -10°F (-23°C), 75W, 80W, 75W-90, 80W-140 REAR: Standard................................................................................................................................... ..........................................................................GL-5 Anti-Spin, Limited-Slip, Powr-Loc, Sure-Grip, Trac-Loc....................................................................... ......................................................................GL-5* FRONT: 4 x 4....................................................................................................................................... .........................................................................GL-5 CAPACITY, Refill: Front: 4-wheel drive Dakota. .............................................................................................................................................................. .................................1.2 Liters 2.6 Pints Spicer 60F axle..................................................................................................................................... ..............................................3.1 Liters 6.5 Pints Others................................................................................................................................................... ..............................................2.7 Liters 5.6 Pints Rear 7 1/4" ring gear with 2 1/2" dia. axle housing adjacent to differential.........................................................................................1.2 Liters 2.5 Pints Spicer 60, 60 HD.................................................................................................................................. ..............................................2.8 Liters 6.0 Pints Spicer 70.............................................................................................................................................. ...............................................3.3 Liters 7.0 Pints Others................................................................................................................................................... ..............................................2.1 Liters 4.5 Pints ANTI-SPIN, LIMITED-SLIP, POWR-LOC, SURE-GRIP OR TRAC-LOC IDENTIFICATION Lift both rear wheels off ground, turn one wheel & other will rotate in same direction Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications Fluid - Transfer Case: Specifications NP205................................................................................................................................................... .........................................GL-5, SF/CC, SF/CD, SG SF/CC, SF/CD, SG:Above 32°F (0°C), 50; below 32°F (0°C), 30 GL-5: Above 90°F (32°C), 140; above -10°F (-23°C), 90; below -10°F (-23°C, 80W NP207, NP208.................................................... ..........................................................................................................................................................A F, AP CAPACITY, Refill: NP205, NP207.............................................................................................. ........................................................................................2.1 Liters 4.5 Pints NP208................................................................................................................................................... ................................................2.8 Liters 6.0 Pints Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - New `SG' Level Oil Engine Oil: Technical Service Bulletins Engine Oil - New `SG' Level Oil Models All 1989 And Earlier Domestic & Import Vehicles Subject New "SG" Quality Engine Oil Index LUBRICATION Date April 24, 1989 No. 10-01-89 (C10-01-9) BODY CODE LEGEND ALL 1989 AND EARLIER CHRYSLER/PLYMOUTH & DODGE DOMESTIC & IMPORT VEHICLES "SG" QUALITY ENGINE OIL The quality of engine oil recommended for use in all Chrysler Motors' vehicles has been upgraded to an "SG" level. The new "SG" quality engine oils can provide significant improvements concerning sludge, varnish and wear control. These new quality oils may also be used in older vehicles where lower quality oils (SE, SF, SF/CC) were recommended. Specific recommendations for all 1989 vehicles may be found in the vehicle "Owners Manual". The new "SG" engine oils are currently being introduced into the MOPAR product line in addition to being commercially available through many automotive supply outlets. POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - New `SG' Level Oil > Page 877 Engine Oil: Technical Service Bulletins Engine - Oil Application Models All Domestic & Import Vehicles Except Turbocharged Subject Use of 5W-30 Engine Oil Index ENGINE Date September 16, 1985 No. 09-17-85 P-3398-C Mopar Max 5W-30 SF/CC oil is now available through Parts Supply. 1. 5W-30 engine oil is recommended for all normal driving conditions up to 100~F ambient temperatures except as noted in (2). This oil provides better engine starting and faster lubrication to engine components at low temperatures than 10W30 or 15W40 oils. 5W-30 oil also provides better fuel economy. 2. SAE 5W-30 and 5W-40 oils are not recommended for use in turbocharged engines, domestic vehicles equipped with the 1.6L engine, nor in trucks (including the Voyager, Caravan & Mini-Ram Van) above 60~F. In addition, these oils are not recommended in cars with 318-4BBL engines at any temperature (police vehicles). The part numbers for Mopar "Max" oil are: 5W-30 SF/CC (quart) PN 4318075 5W-30 SF/CC (drum) PN 4318076 5W-30 oil is now used as the factory fill in most Chrysler Corporation vehicles. POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Page 878 Engine Oil: Specifications TYPE.................................................................................................................................................... ....................................................SF/CC, SF/CD, SG CAPACITY, Refill: 4-cyl.................................... ...........................................................................................................................................................3. 8 Liters 4.0 Quarts All Others............................................................................................................... ...........................................................................4.7 Liters 5.0 Quarts Capacity shown is without filter. When replacing filter, additional oil may be needed Above 20°F (-7°C).......................................................................................................................10W-30, 10W-40, 10W-50, 15W-40, 20W-40, 20W-50 30 20° to 80°F (-7° to 27°C)........................................................ .....................................................................................................................................20W-20 Above 10°F (-12°C)......................................................................................................................................... ............................................................15W-40 Above 0° F (-18°C)..................................................... ...................................................................................................................10W-30, 10W-40, 10W-50 Below 60°F (16°C)................................................................................................................................ ...........................................................5W-30, 5W-40 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications REFRIGERANT CAPACITIES DODGE/PLYMOUTH TRUCKS 1992 Ram 50 pickup ............................................................................................................................ .............................................. 0.8 kg (30 oz.) Ramcharger .................................................................. ............................................................................................................. 1.3 kg (44 oz.) 1992-91 Dakota ................................................................................................................................... ................................................... 1.2 kg (40 oz.) B-Series van ............................................................ .................................................................................................................. 1.3 kg (44 oz.) with rear unit ....................................................................................................................................................... ...................... 1.8 kg (62 oz.) 1992-90 Caravan, Mini Ram, Voyager ................................................................................................................................................... 0.9 kg (32 oz.) with rear unit ........................................................................................................................... .................................................. 1.2 kg (43 oz.) 1992-88 D/W-Series pickup ................................................................................................................. .................................................. 1.3 kg (44 oz.) 1990-87 Dakota ................................................................................................................................... ................................................... 1.3 kg (44 oz.) 1990-83 B-Series van .......................................................................................................................... .................................................... 1.4 kg (48 oz.) with rear unit ........................................................... .................................................................................................................. 1.8 kg (62 oz.) 1989-84 Caravan, Mini-Ram, Voyager ................................................................................................................................................... 1.1 kg (38 oz.) with rear AC ............................................................................................................................ ................................................. 1.3 kg (44 oz.) 1987-83 D/W-Series pickup ................................................................................................................. .................................................. 1.1 kg (40 oz.) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 883 Refrigerant: Fluid Type Specifications A/C Refrigerant Specifications A/C Refrigerant Specifications Refrigerant Types R-12 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications Refrigerant Oil: Specifications Capacities Capacities Capasity Viscosity 7-7.25 oz (US) 500 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding Brake Bleeding: Service and Repair About Brake System Bleeding WHEN BLEEDING BRAKES REMEMBER... - Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender covers to protect the vehicle's finish and electrical system. - Always flush and bleed the brake hydraulic sys. when servicing the brakes, because: Brake fluid absorbs moisture from the air, after 3-4 years of service the water content of the brake fluid may be as high as 6-7%. This significantly reduces the boiling point of the brake fluid which may result in a soft pedal or brake failure during prolonged or severe braking. Corrosion deposits and other contaminants gradually build up inside of the brake hydraulic sys. Check the bottom of the master-cylinder reservoir for a build up of fine black silt. If any is present the brake fluid should be flushed. - Never reuse brake fluid that has been drained from the brake system. DOT 3,4 or DOT 5 As a general rule DOT 5 brake fluid should not be used in vehicles recommending DOT 3 or 4 type fluid. DOT 5 brake fluid is silicone based. DOT 3 (standard) and DOT 4 (heavy-duty) are glycol-based. DOT 5 can be distinguished from conventional brake fluids by its purple color (which comes from a dye). DOT 5 silicone brake fluid won't mix with glycol-based brake fluid (creating concern over sludging if all old fluid isn't removed when a system is refilled with silicone). Silicone does not absorb moisture. DOT 5 brake fluid does not become contaminated with moisture over time as conventional DOT 3 and 4 brake fluids do. Silicone is also chemically inert, nontoxic and won't damage paint like conventional brake fluid. It also has a higher boiling point. Because of this, it is often marketed as a premium "lifetime" brake fluid. It is often used to preserve brake systems in antique vehicles and those that sit for long periods of time between use. Silicone also has slightly different physical properties and compressibility, making it unsuitable for ABS systems calibrated to work with DOT 3 or 4 brake fluid. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 891 Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures Fig 2 Extending Valve Stem NOTE: All vehicles are equipped with a pressure hold-off valve. The valve is located (in the combination valve) on the left frame rail. The hold off valve balances front and rear braking force to improve braking and steering control on icy surfaces. The valve shuts off the flow of brake fluid between 3 and 135 PSI. Because the valve shuts off flow in this pressure range the valve must be held open manually -- using tool C-4121 or equivalent -- when pressure bleeding the system. CAUTION: Under no circumstances should a rigid clamp, wedge or block be used to depress the valve stem. This could cause an internal valve failure resulting in complete loss of front brakes. 1. Clean all dirt and foreign material from the cover of the master cylinder to prevent dirt from falling into the master cylinder reservoir when the cover is removed. 2. Install metering valve hands off tool, part No. C-4121 to valve stem of metering valve. NOTE: Complete bleeding of dual master cylinder is important before performing this procedure! 3. Starting with RWAL hydraulic valve, clean all dirt from the bleeder valve. 4. Place bleeder hose on the bleeder valve and insert the other end of the bleeder hose into a clear jar half filled with clean brake fluid. This will permit the observation of air bubbles as they are being expelled from the hydraulic system and also prevent air from being drawn back into the system. 5. Continue this bleeding with: a. The right rear wheel b. Then left rear wheel c. Next, bleed the right front and d. Finish with the left front wheel 6. Repeat this bleeding procedure if there is any indication of air remaining in the hydraulic system: - Spongy brake pedal - Warning light ON CAUTION: The pressure release valve is in its innermost position when there is no pressure present. No attempt should be made to further depress the valve stem. NOTE: If diagnosis determines that master cylinder alone is cause of trouble, it can be replaced without bleeding the hydraulic system provided the replacement cylinder is completely bled before installation. After brake tubes are connected have helper apply force to pedal while both tube nuts are cracked to release any air and then retightened. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 892 Brake Bleeding: Service and Repair Pressure Bleeding (Preferred Procedure) Fig 2 Extending Valve Stem NOTE: All vehicles are equipped with a pressure hold-off valve. The valve is located (in the combination valve) on the left frame rail. The hold off valve balances front and rear braking force to improve braking and steering control on icy surfaces. The valve shuts off the flow of brake fluid between 3 and 135 PSI. Because the valve shuts off flow in this pressure range the valve must be held open manually -- using tool C-4121 or equivalent -- when pressure bleeding the system. CAUTION: Under no circumstances should a rigid clamp, wedge or block be used to depress the valve stem. This could cause an internal valve failure resulting in complete loss of front brakes. 1. Clean all dirt and foreign material from the cover of the master cylinder to prevent dirt from falling into the master cylinder reservoir when the cover is removed. 2. Install metering valve hands off tool, part No. C-4121 to valve stem of metering valve. NOTE: Complete bleeding of dual master cylinder is important before performing this procedure! 3. Starting with RWAL hydraulic valve, clean all dirt from the bleeder valve. 4. Place bleeder hose on the bleeder valve and insert the other end of the bleeder hose into a clear jar half filled with clean brake fluid. This will permit the observation of air bubbles as they are being expelled from the hydraulic system and also prevent air from being drawn back into the system. 4. Continue this bleeding with: a. The left rear wheel. b. Next, bleed the right front. c. Finish with the left front wheel. 6. Repeat this bleeding procedure if there is any indication of air remaining in the hydraulic system: - Spongy brake pedal - Warning light ON CAUTION: The pressure release valve is in its innermost position when there is no pressure present. No attempt should be made to further depress the valve stem. NOTE: If diagnosis determines that master cylinder alone is cause of trouble, it can be replaced without bleeding the hydraulic system provided the replacement cylinder is completely bled before installation. After brake tubes are connected have helper apply force to pedal while both tube nuts are cracked to release any air and then retightened. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations Door Lock And Power Window Circuit Breaker And Relays Location The circuit breaker is located behind the dash panel, in cavity # 10 of the fuse block. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Page 897 Circuit Breaker: Testing and Inspection Door Lock And Power Window Circuit Breaker And Relays Location To test the circuit breaker, connect the negative lead of a voltmeter to a known good ground, and touch the positive lead to one terminal of the circuit breaker. If battery voltage is present, test the other terminal of the circuit breaker. If battery voltage is present on only one terminal, then the circuit breaker is defective. If battery voltage is present on neither terminal, check for a burned fusible link or power lead wire to the circuit breaker. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Page 898 Circuit Breaker: Service and Repair Door Lock And Power Window Circuit Breaker And Relays Location Remove the four screws that attach the lower steering column cover to the dash panel. Locate the circuit breaker in cavity # 10 and pull it out. Use a test light check for power in cavity # 10. Power should be present only on one terminal. Install the new circuit breaker by pushing it in slowly, making certain that both terminals hold snugly. Power should now be present at both terminals. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Testing and Inspection Fuse: Testing and Inspection Door Lock And Power Window Circuit Breaker And Relays Location To test the circuit breaker, connect the negative lead of a voltmeter to a known good ground, and touch the positive lead to one terminal of the circuit breaker. If battery voltage is present, test the other terminal of the circuit breaker. If battery voltage is present on only one terminal, then the circuit breaker is defective. If battery voltage is present on neither terminal, check for a burned fusible link or power lead wire to the circuit breaker. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Testing and Inspection > Page 902 Fuse: Service and Repair Circuit Breaker/Fuse Replacement Door Lock And Power Window Circuit Breaker And Relays Location Remove the four screws that attach the lower steering column cover to the dash panel. Locate the circuit breaker in cavity # 10 and pull it out. Use a test light check for power in cavity # 10. Power should be present only on one terminal. Install the new circuit breaker by pushing it in slowly, making certain that both terminals hold snugly. Power should now be present at both terminals. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 907 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 908 Fig. 1 Fuse Panel. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Service Reminder Indicator Light <--> [Emissions Maintenance Light] > Emissions Maintenance Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Emissions Maintenance Lamp Relay: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Service Reminder Indicator Light <--> [Emissions Maintenance Light] > Emissions Maintenance Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 915 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair This reminder uses mileage impulse counting contacts to calculate maintenance intervals. The module is located to the right of the steering column. After necessary emission maintenance has been performed, reset module as follows: 1. Slide module from bracket. 2. Insert a small screwdriver into small hole on module case and close switch. 3. Remove module battery cover and install a replacement 9 volt battery. 4. Position module on mounting bracket. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Testing and Inspection Oil Level Warning Indicator: Testing and Inspection Remote Recreational Vehicle Sensor Package Fig. 3 Recreational vehicle sensor package instrument cluster. 1980 Fig. 4 Recreational vehicle sensor package instrument cluster. 1981-82 The recreational vehicle sensor package consists of a separate instrument cluster which allows the driver to monitor the following conditions: engine oil level, engine coolant level, transmission fluid level and transmission fluid temperature. TROUBLESHOOTING VOLTAGE LIMITER TEST 1. Connect voltmeter between temperature sending unit (locating in fitting in bottom radiator tank) and a suitable ground. Do not disconnect electrical connector from sending unit. 2. Turn ignition switch to On position and observe voltmeter. 3. If voltmeter needle fluctuates, the voltage limiter is operating properly. 4. If voltmeter does not fluctuate, replace voltage limiter. The voltage limiter is located on the sensor panel. To gain access to the limiter, remove panel and unsnap the back cover. TEMPERATURE GAUGE TEST 1. Disconnect electrical connector from temperature sending unit in lower radiator tank. 2. Connect tester No. C-3826 or equivalent between temperature sending unit and a suitable ground. 3. Move tester pointer to "C" position, then turn ignition switch On and observe temperature gauge. Temperature gauge should read within 1/8 inch of "C". 4. Move tester pointer to "M" position. Temperature gauge should now advance to normal range left of 1/2 position on dial. 5. Move tester pointer to "H" position. Temperature gauge should now advance to "H" position on dial. 6. If temperature gauge responds to tests described in steps 3, 4 and 5, but does not operate when sending unit electrical connector is attached, the sending unit is defective and should be replaced. 7. If temperature gauge does not respond to tests described in steps 3, 4 and 5, check for loose connections, broken wire, open printed circuit or faulty gauge. OIL LEVEL PUSH BUTTON SWITCH 1. Inspect switch for poor solder connections and repair or replace as necessary. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Testing and Inspection > Page 922 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the switch should be replaced. To replace switch, remove circuit board and push switch toward back of sensor housing. PRINTED CIRCUIT BOARD 1. Inspect conductors for cracks or damaged circuits. 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the sensor panel assembly should be replaced. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments EXC. MOTOR HOME & 4 WHEEL DRIVE 1. Torque adjusting nut to 360-480 inch lbs. for Vans, Wagons and Front Sections or 90 inch lbs. for Ramcharger, Trail Duster and Conventional Cabs while rotating wheel. 2. Stop wheel from rotating, then back off adjusting nut to completely release bearing preload. 3. Tighten adjusting nut finger tight, then install locknut and cotter key. End play should be 0.0001 to 0.003 inch. 4. Clean grease cap, coat inside with suitable wheel bearing grease and install cap. Do not fill cap with grease. MOTOR HOME 1. Rotate wheel and tighten adjusting nut until a slight binding is felt. 2. Back off adjusting nut so that the nearest slot indexes with the cotter pin hole in the spindle. Never back off adjusting nut less than half the distance from one slot to the next slot. 3. Install cotter pin to locknut and ensure that wheel rotates freely. 4 WHEEL DRIVE SPICER 44FBJ & 44-8FD Axle 1. Raise and support vehicle. 2. Remove locking hub assembly, then the wheel bearing locknut and washer. 3. Torque adjusting nut to 50 ft. lbs., using tool No. C-4170 or equivalent, to seat the bearing. 4. Loosen adjusting nut and retorque to 30-40 ft. lbs. while rotating hub, then back off adjusting nut 135°-150°. 5. Install retaining washer and bearing locknut. Torque locknut to 50 ft. lbs. Endplay should be 0.001 to 0.010 inch. SPICER 60 Axle 1. Raise and support vehicle. 2. Remove hub cap, then the snap ring using suitable pliers. 3. Remove flange nuts and lock washers, then the drive flange or locking hub if equipped. 4. Straighten tang on lock ring, then using tool No. DD-1241-JD or equivalent, remove outer locknut and lock ring. 5. Torque locknut to 50 ft. lbs. to seat the bearing, loosen locknut and retorque to 30-40 ft. lbs. Back off locknut 135°-150°. 6. Install lock ring and outer locknut. Torque locknut to 65 ft. lbs. 7. Bend tangs of long ring over both locknuts. Endplay should be 0.001 to 0.010 inch. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Except Model 60 and 70 rear axles Coned nut with 1/2 x 20 thread ....................................................................................................................................................... 105 ft lb (142 Nm) Model 60 and 70 rear axles Coned nut with 5/8 x 18 thread ......................................................................................................................................... 175-225 ft lb (217-305 Nm) Flanged nut with 5/8 x 18 thread ...................................................................................................................................... 300-350 ft lb (407-475 Nm) Flanged nut with 1 1/8 x 16 thread ................................................................................................................................... 450-500 ft lb (610-678 Nm) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression Check Specifications Compression Check Specifications Compression Pressure 100 psi At cranking speed, engine temperature normalized, throttle Note: Minimum open Maximum Variation 25 psi Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Gear Bolt 35 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Bearing Clearance and Endplay Camshaft: Specifications Bearing Clearance and Endplay Bearing Clearance and Endplay Camshaft Bearing Clearance .001-.003 in Camshaft Endplay .002-.010 in Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Bearing Clearance and Endplay > Page 943 Camshaft: Specifications Valve Timing 10 deg BTDC Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 944 Camshaft: Service and Repair NOTE: When removing camshaft or bearings, it is recommended that the engine be removed from chassis. Fig. 17 Camshaft assembly. V8-318 (5.2L) & V8-360 (5.9L) V8-318 (5.2L) & V8-360 5.9L Removal 1. Remove intake manifold, cylinder head covers, timing chain cover and timing chain. 2. Remove rocker arm and shaft assemblies. 3. Remove pushrods and lifters using suitable tool. Identify lifters to ensure correct position during installation. 4. Remove distributor, then lift out oil pump and distributor driveshaft. 5. Remove camshaft thrust plate noting location of oil tab. 6. Install long bolt into front of camshaft to facilitate removal, then remove camshaft from engine, Fig. 17. Fig. 18 Install camshaft holding tool Installation 1. Lubricate camshaft lobes and bearing journals, then install camshaft within two inches of final position in cylinder block. 2. Install tool No. C-3509 as shown in Fig. 18. 3. Hold tool in position with distributor lock plate screw. Tool should remain installed until camshaft, crankshaft sprockets and timing chain have been installed. 4. Install camshaft thrust plate and chain oil tab attaching screws, ensuring tang enters lower right hole in thrust plate, then torque attaching screws to 210 inch lbs. Top edge of tab should be flat against thrust plate in order to catch oil for chain lubrication. 5. Install timing chain, refer to ``Timing Gears Or Chain'' procedure. 6. Install fuel pump eccentric, cup washer and camshaft bolt. Torque bolt to 35 ft. lbs. 7. Reverse remaining procedure to assemble. V8-446 (7.3L) 1. Remove oil pump and distributor. 2. Remove valve lifters, water pump, crankshaft pulley and damper, then the timing case cover. 3. Remove camshaft thrust flange attaching bolts, then the camshaft. Use caution when handling camshaft assembly to prevent chipping distributor gear teeth. 4. Reverse procedure to install. To align timing marks refer to ``Timing Gears Or Chain, Replace'' procedure. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Hydraulic Lash Adjuster <--> [Lifter / Lash Adjuster, Valve] > Component Information > Specifications Hydraulic Lash Adjuster: Specifications Lifter Bore Diameter .9051-.9059 in Lifter Diameter .9035-.9040 in Lifter To Bore Clearance .0011-.0024 in Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Hydraulic Lash Adjuster <--> [Lifter / Lash Adjuster, Valve] > Component Information > Specifications > Page 948 Hydraulic Lash Adjuster: Service and Repair Fig. 10 Hydraulic valve lifter. 1980-87 exc. V8-446 (7.3L) Fig. 11 Hydraulic valve lifter. V8-446 (7.3L) Figs. 10 and 11 illustrate the type of hydraulic valve lifters used. Before disassembling any part of the engine to check for noise, check the oil pressure at the gauge and the oil level in the oil pan. The oil level in the pan should never be above the ``full'' mark on the dipstick, nor below the ``add oil'' mark. Either of the two conditions could be responsible for noisy lifters. Fig. 12 Removing stuck hydraulic lifter with special tool. Typical LIFTER, REPLACE Worn valve guides or cocked springs are sometimes mistaken for noisy lifters. Determine which lifter is noisy. If the application of side thrust on the valve spring fails to noticeably reduce the noise, the lifter is probably faulty and should be removed for inspection. Removal of stuck lifters requires a special tool, Fig. 12. When installing hydraulic lifters in the engine, fill them with light engine oil to avoid excessive time required to quiet them during initial operation of engine. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Bolts 23 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 952 Rocker Arm Assembly: Service and Repair When disassembling rocker arms, place all parts on the workbench in their proper sequence to ensure correct assembly. Clean all sludge and gum formation from the inside and outside of the shafts. Clean oil holes and passages in the rocker arms and shafts. Inspect the shafts for wear. Fig. 8 Rocker arm and shaft assembly installed. V8-318 (5.2L) & V8-360 (5.9L) V8-318 (5.2L) & V8-360 (5.9L) To provide proper lubrication of the rocker arms, the rocker shafts have a small notch machined at one end. Install rocker arm and shaft assemblies with notch on end of rocker shaft pointing to center line of engine and toward front of engine on the left bank and to the rear on the right bank. If rocker arms are removed from shaft, care must be taken to ensure proper reassembly. Some exhaust rocker arms have a relieved area on the underside for rotator clearance. Refer to Fig. 8 for proper positioning of rocker arms. Note placement of long stamped steel retainers in the number two and four positions between the rocker arms. Fig. 9 Rocker arm and shaft assembly. V8-446 (7.3L) V8-446 (7.3L) The rocker arms on these engines are individually mounted and are retained by flange head bolts and pivot balls. Install the rocker arm components in original position, Fig. 9. Inspect the pivot surfaces of the rocker arms and pivot balls for signs of scuffing, pitting or excessive wear. Inspect the valve stem contact surface of the rocker arms for pitting. Replace any component found unsatisfactory. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications EXC. V8-446 (7.3L) Main bearings are furnished in standard sizes and the following undersizes: 0.001, 0.002, 0.003, 0.010, 0.012 inch. Rod bearings are furnished in standard sizes and the following undersizes: 0.001, 0.002, 0.003, 0.010, 0.012 inch. V8-446 (7.3L) Main and rod bearings are furnished in standard sizes and the following undersizes: 0.010, 0.020, 0.030 inch. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Cap Bolts/Nuts Connecting Rod: Specifications Connecting Rod Nut Torque 45 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Cap Bolts/Nuts > Page 961 Connecting Rod: Specifications Pin Bore Diameter and Side Clearance Pin Bore Diameter and Side Clearance Pin Bore Diameter .9829-.9834 in Side Clearance .006-.014 in Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 962 Connecting Rod: Service and Repair Fig. 20 Correct assembly of pistons and rods. V8 engines exc. V8-446 (7.3L) ALL V8 ENGINES EXC. V8-446 (7.3L) When installing piston and rod assemblies in the cylinders, the compression ring gaps should be diametrically opposite one another and not in line with the oil ring gap. The oil ring expander gap should be toward the outside of the ``V'' of the engine. The oil ring gap should be turned toward the inside of the engine ``V''. Immerse the piston head and rings in clean engine oil and, with a suitable piston ring compressor, insert the piston and rod assembly into the bore. Tap the piston down into the bore, using the handle of a hammer. Assemble and install the pistons and rods as shown in Fig. 20. Fig. 21 Piston & rod assembly. V8-446 (7.3L) V8-446 (7.3L) Before disassembling, mark piston on same side as large chamfer on connecting rod, so they can be assembled in the same position. New pistons may be installed either way on connecting rod, Fig. 21. When installing piston in engine the large chamfered side of each connecting rod must be located against the crankshaft face. The chamfer provides clearance at the crankshaft fillet. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications EXC. V8-446 (7.3L) Main bearings are furnished in standard sizes and the following undersizes: 0.001, 0.002, 0.003, 0.010, 0.012 inch. Rod bearings are furnished in standard sizes and the following undersizes: 0.001, 0.002, 0.003, 0.010, 0.012 inch. V8-446 (7.3L) Main and rod bearings are furnished in standard sizes and the following undersizes: 0.010, 0.020, 0.030 inch. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Crankshaft Journal Tolerances Crankshaft: Specifications Main and Rod Journal Diameters Main and Rod Journal Diameters Main Journal Diameter 2.4995-2.5005 in Rod Journal Diameter 2.124-2.125 in Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Crankshaft Journal Tolerances > Page 970 Crankshaft: Specifications Crankshaft Main Bearing Caps 85 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Balancer Bolt Torque Balancer Bolt Torque Vibration Damper Or Pulley 100 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Piston Clearance Piston: Specifications Piston Clearance .0005-.0015 in Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Piston Clearance > Page 978 Piston: Specifications Piston, Pin & Ring Sizes Available EXC. V8-446 (7.3L) Pistons are available in standard sizes and .020 inch oversize. Pins are available in the following oversizes: V8-318 (5.2L) & V8-360 (5.9L): 0.003, 0.008 inch. Oversize pins are not available on other engines. Rings are available in the following oversizes: STD to 0.009, 0.020 - 0.029, 0.040 - 0.049 inch. V8-446 (7.3L) Pistons are available in standard sizes and the following oversizes: 0.010, 0.020, 0.030 inch. Oversize pins are not available. Rings are available in the following oversizes: 0.010, 0.020, 0.030 inch. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 979 Piston: Service and Repair Fig. 20 Correct assembly of pistons and rods. V8 engines exc. V8-446 (7.3L) ALL V8 ENGINES EXC. V8-446 (7.3L) When installing piston and rod assemblies in the cylinders, the compression ring gaps should be diametrically opposite one another and not in line with the oil ring gap. The oil ring expander gap should be toward the outside of the ``V'' of the engine. The oil ring gap should be turned toward the inside of the engine ``V''. Immerse the piston head and rings in clean engine oil and, with a suitable piston ring compressor, insert the piston and rod assembly into the bore. Tap the piston down into the bore, using the handle of a hammer. Assemble and install the pistons and rods as shown in Fig. 20. Fig. 21 Piston & rod assembly. V8-446 (7.3L) V8-446 (7.3L) Before disassembling, mark piston on same side as large chamfer on connecting rod, so they can be assembled in the same position. New pistons may be installed either way on connecting rod, Fig. 21. When installing piston in engine the large chamfered side of each connecting rod must be located against the crankshaft face. The chamfer provides clearance at the crankshaft fillet. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications EXC. V8-446 (7.3L) Pistons are available in standard sizes and .020 inch oversize. Pins are available in the following oversizes: V8-318 (5.2L) & V8-360 (5.9L): 0.003, 0.008 inch. Oversize pins are not available on other engines. Rings are available in the following oversizes: STD to 0.009, 0.020 - 0.029, 0.040 - 0.049 inch. V8-446 (7.3L) Pistons are available in standard sizes and the following oversizes: 0.010, 0.020, 0.030 inch. Oversize pins are not available. Rings are available in the following oversizes: 0.010, 0.020, 0.030 inch. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Piston Ring Dimensions Piston Ring: Specifications Piston Ring End Gap, Comp. 0.01 in Note: Minimum Piston Ring End Gap, Oil 0.015 in Piston Ring Side Clearance, Comp. .0015-.004 in Piston Ring Side Clearance, Oil .0002-.005 in Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Piston Ring Dimensions > Page 987 Piston Ring: Specifications Piston, Pin & Ring Sizes Available EXC. V8-446 (7.3L) Pistons are available in standard sizes and .020 inch oversize. Pins are available in the following oversizes: V8-318 (5.2L) & V8-360 (5.9L): 0.003, 0.008 inch. Oversize pins are not available on other engines. Rings are available in the following oversizes: STD to 0.009, 0.020 - 0.029, 0.040 - 0.049 inch. V8-446 (7.3L) Pistons are available in standard sizes and the following oversizes: 0.010, 0.020, 0.030 inch. Oversize pins are not available. Rings are available in the following oversizes: 0.010, 0.020, 0.030 inch. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments 1981-87 6-225 (3.7L) & ALL 1980-87 V8 ENGINES These engines are equipped with hydraulic lifters. No provision for adjustment is provided. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Bolts 23 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 995 Rocker Arm Assembly: Service and Repair When disassembling rocker arms, place all parts on the workbench in their proper sequence to ensure correct assembly. Clean all sludge and gum formation from the inside and outside of the shafts. Clean oil holes and passages in the rocker arms and shafts. Inspect the shafts for wear. Fig. 8 Rocker arm and shaft assembly installed. V8-318 (5.2L) & V8-360 (5.9L) V8-318 (5.2L) & V8-360 (5.9L) To provide proper lubrication of the rocker arms, the rocker shafts have a small notch machined at one end. Install rocker arm and shaft assemblies with notch on end of rocker shaft pointing to center line of engine and toward front of engine on the left bank and to the rear on the right bank. If rocker arms are removed from shaft, care must be taken to ensure proper reassembly. Some exhaust rocker arms have a relieved area on the underside for rotator clearance. Refer to Fig. 8 for proper positioning of rocker arms. Note placement of long stamped steel retainers in the number two and four positions between the rocker arms. Fig. 9 Rocker arm and shaft assembly. V8-446 (7.3L) V8-446 (7.3L) The rocker arms on these engines are individually mounted and are retained by flange head bolts and pivot balls. Install the rocker arm components in original position, Fig. 9. Inspect the pivot surfaces of the rocker arms and pivot balls for signs of scuffing, pitting or excessive wear. Inspect the valve stem contact surface of the rocker arms for pitting. Replace any component found unsatisfactory. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Valve Cover Bolts 80 in.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Seat Angle 45-45.5° deg Seat Width Intake .065-.085[7] in Exhaust .080-.100 in Runout 0.003 in Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Valve Spring Installed Height Valve Spring Installed Height Installed Height 1.625-1.6875 in Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > General Valve Specifications Valve: Specifications Valve Stem Height Specifications Valve Stem Height Specifications Valve Stem Installed Height 1 5/8 - 1 11/16 in Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > General Valve Specifications > Page 1009 Valve: Specifications Stem Diameter Intake .372-.373 in Stem Diameter Exhaust .371-.372 in Face Angle 44.5-45 deg Margin Intake 0.0469 in Margin Exhaust 0.0469 in Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications Drive Belt: Specifications A belt in operation for 15 minutes is considered a used belt. Strand Tension method: Use gauge. Measurements are in pounds. Used belts, 70; New belts, 120. Deflection method: One-fourth to one-half of a inch or 6-12 millimeters with 10 lbs. of force applied at midpoint of belt. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 090286 > Feb > 86 > Engine/Transmission -Droning/Moaning Noise Engine Mount: Customer Interest Engine/Transmission -Droning/Moaning Noise No. 09-02-86 P-672 Date February 24, 1986 Index ENGINE Subject "Moan or Drone" at 1600-2100 Engine RPM Models 1984-1986 Rear Wheel Drive Domestic Passenger Cars 1981-1986 "D" Series Trucks With Automatic Transmission SYMPTOM/CONDITION Passenger Car & Truck These vehicles may exhibit a moaning or droning noise which occurs at approximately 1800 engine rpm (for V8 engines), or 2100 rpm (for 6- cylinder engines), in any gear. This noise is sometimes misdiagnosed as an "exhaust system drone", it is not always caused by the exhaust system. Addition of a damper weight to the rear of the transmission extension can help reduce this noise. Only the A904/A999 transmission extension has provision for mounting this weight; it cannot be used with the A727 transmission. Truck Only A new rear engine mount insulator, which also reduces the moaning noise. It can be used on all trucks, including those with the A727 transmission. Trucks with the A904/A999 transmission can use the weight, and the rear engine mount. PARTS REQUIRED For all subject trucks: 1 Engine Rear Support Insulator Assembly PN 4412962 (A904, 999 and 727 transmission) 2 Screw/Washer Assembly PN 6029770 For trucks or passenger cars with A904/A999 transmission order: 1 Damper Weight Assembly PN 4412542 1 Plate PN 3681614 2 Washers PN 6032046 2 Screws - PN 6032047 REPAIR PROCEDURE It will be necessary to install a damper weight and/or rear transmission support to correct this condition. Truck 1. To replace the engine rear support insulator assembly: a. With the vehicle on a hoist, position a transmission jack and raise the rear of the transmission and engine slightly. b. Remove the rear mount through-bolt. c. Remove the insulator assembly and spacers from the bottom of the transmission extension housing. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 090286 > Feb > 86 > Engine/Transmission -Droning/Moaning Noise > Page 1022 d. Install the new insulator assembly on the transmission extension, with the spacers between the screws and the insulator bracket. Use new screws and torque them to 50 foot pounds. e. Reinstall the rear mount through-bolt and torque to 50 foot pounds. f. Remove the transmission jack. 2. To install the damper weight assembly: a. Position the damper weight assembly and plate on the mounting pad at the extreme rear end of the transmission extension. The plate must be in between the weight and the transmission extension. b. Install the screws and washers as shown in Figure 1, and torque the screws to 150 inch pounds. Passenger Car 1. Remove existing damper weight from transmission extension. 2. Install new damper weight, making sure that spacers and washers are installed as shown in Figure 1. Torque screws to 150 inch pounds. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 21-95-40-91 0.2 Hrs. FAILURE CODE: OX - Wrong Part Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 090286 > Feb > 86 > Engine/Transmission -Droning/Moaning Noise Engine Mount: All Technical Service Bulletins Engine/Transmission -Droning/Moaning Noise No. 09-02-86 P-672 Date February 24, 1986 Index ENGINE Subject "Moan or Drone" at 1600-2100 Engine RPM Models 1984-1986 Rear Wheel Drive Domestic Passenger Cars 1981-1986 "D" Series Trucks With Automatic Transmission SYMPTOM/CONDITION Passenger Car & Truck These vehicles may exhibit a moaning or droning noise which occurs at approximately 1800 engine rpm (for V8 engines), or 2100 rpm (for 6- cylinder engines), in any gear. This noise is sometimes misdiagnosed as an "exhaust system drone", it is not always caused by the exhaust system. Addition of a damper weight to the rear of the transmission extension can help reduce this noise. Only the A904/A999 transmission extension has provision for mounting this weight; it cannot be used with the A727 transmission. Truck Only A new rear engine mount insulator, which also reduces the moaning noise. It can be used on all trucks, including those with the A727 transmission. Trucks with the A904/A999 transmission can use the weight, and the rear engine mount. PARTS REQUIRED For all subject trucks: 1 Engine Rear Support Insulator Assembly PN 4412962 (A904, 999 and 727 transmission) 2 Screw/Washer Assembly PN 6029770 For trucks or passenger cars with A904/A999 transmission order: 1 Damper Weight Assembly PN 4412542 1 Plate PN 3681614 2 Washers PN 6032046 2 Screws - PN 6032047 REPAIR PROCEDURE It will be necessary to install a damper weight and/or rear transmission support to correct this condition. Truck 1. To replace the engine rear support insulator assembly: a. With the vehicle on a hoist, position a transmission jack and raise the rear of the transmission and engine slightly. b. Remove the rear mount through-bolt. c. Remove the insulator assembly and spacers from the bottom of the transmission extension housing. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 090286 > Feb > 86 > Engine/Transmission -Droning/Moaning Noise > Page 1028 d. Install the new insulator assembly on the transmission extension, with the spacers between the screws and the insulator bracket. Use new screws and torque them to 50 foot pounds. e. Reinstall the rear mount through-bolt and torque to 50 foot pounds. f. Remove the transmission jack. 2. To install the damper weight assembly: a. Position the damper weight assembly and plate on the mounting pad at the extreme rear end of the transmission extension. The plate must be in between the weight and the transmission extension. b. Install the screws and washers as shown in Figure 1, and torque the screws to 150 inch pounds. Passenger Car 1. Remove existing damper weight from transmission extension. 2. Install new damper weight, making sure that spacers and washers are installed as shown in Figure 1. Torque screws to 150 inch pounds. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 21-95-40-91 0.2 Hrs. FAILURE CODE: OX - Wrong Part Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 1029 Engine Mount: Service and Repair FRONT 1. Raise hood, then position fan and related components to ensure necessary clearance. 2. Raise and support vehicle, then attach a suitable lifting device to engine. 3. Remove engine mount to frame attaching nuts. 4. Raise engine slightly, then remove mounts. Some models incorporate a insulator between the engine mount and engine mount attaching bracket. 5. Reverse procedure to install. Torque attaching nuts to 75 ft. lbs. and attaching bolts to 65 ft. lbs. REAR 1. Raise hood, then position fan and related components to ensure necessary clearance. 2. Raise and support vehicle, position a suitable jack under transmission assembly. 3. Slightly raise transmission and engine assembly, then remove rear mount through bolts. 4. Remove U-shaped bracket from frame cross member. 5. Remove insulator from bottom face of transmission extension housing. 6. Reverse procedure to install. Torque attaching nuts to 75 ft. lbs. and attaching bolts to 65 ft. lbs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Engine Oil Drain Plug: Specifications Oil Drain Plug 25 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - New `SG' Level Oil Engine Oil: Technical Service Bulletins Engine Oil - New `SG' Level Oil Models All 1989 And Earlier Domestic & Import Vehicles Subject New "SG" Quality Engine Oil Index LUBRICATION Date April 24, 1989 No. 10-01-89 (C10-01-9) BODY CODE LEGEND ALL 1989 AND EARLIER CHRYSLER/PLYMOUTH & DODGE DOMESTIC & IMPORT VEHICLES "SG" QUALITY ENGINE OIL The quality of engine oil recommended for use in all Chrysler Motors' vehicles has been upgraded to an "SG" level. The new "SG" quality engine oils can provide significant improvements concerning sludge, varnish and wear control. These new quality oils may also be used in older vehicles where lower quality oils (SE, SF, SF/CC) were recommended. Specific recommendations for all 1989 vehicles may be found in the vehicle "Owners Manual". The new "SG" engine oils are currently being introduced into the MOPAR product line in addition to being commercially available through many automotive supply outlets. POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - New `SG' Level Oil > Page 1038 Engine Oil: Technical Service Bulletins Engine - Oil Application Models All Domestic & Import Vehicles Except Turbocharged Subject Use of 5W-30 Engine Oil Index ENGINE Date September 16, 1985 No. 09-17-85 P-3398-C Mopar Max 5W-30 SF/CC oil is now available through Parts Supply. 1. 5W-30 engine oil is recommended for all normal driving conditions up to 100~F ambient temperatures except as noted in (2). This oil provides better engine starting and faster lubrication to engine components at low temperatures than 10W30 or 15W40 oils. 5W-30 oil also provides better fuel economy. 2. SAE 5W-30 and 5W-40 oils are not recommended for use in turbocharged engines, domestic vehicles equipped with the 1.6L engine, nor in trucks (including the Voyager, Caravan & Mini-Ram Van) above 60~F. In addition, these oils are not recommended in cars with 318-4BBL engines at any temperature (police vehicles). The part numbers for Mopar "Max" oil are: 5W-30 SF/CC (quart) PN 4318075 5W-30 SF/CC (drum) PN 4318076 5W-30 oil is now used as the factory fill in most Chrysler Corporation vehicles. POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Page 1039 Engine Oil: Specifications TYPE.................................................................................................................................................... ....................................................SF/CC, SF/CD, SG CAPACITY, Refill: 4-cyl.................................... ...........................................................................................................................................................3. 8 Liters 4.0 Quarts All Others............................................................................................................... ...........................................................................4.7 Liters 5.0 Quarts Capacity shown is without filter. When replacing filter, additional oil may be needed Above 20°F (-7°C).......................................................................................................................10W-30, 10W-40, 10W-50, 15W-40, 20W-40, 20W-50 30 20° to 80°F (-7° to 27°C)........................................................ .....................................................................................................................................20W-20 Above 10°F (-12°C)......................................................................................................................................... ............................................................15W-40 Above 0° F (-18°C)..................................................... ...................................................................................................................10W-30, 10W-40, 10W-50 Below 60°F (16°C)................................................................................................................................ ...........................................................5W-30, 5W-40 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Testing and Inspection Oil Level Warning Indicator: Testing and Inspection Remote Recreational Vehicle Sensor Package Fig. 3 Recreational vehicle sensor package instrument cluster. 1980 Fig. 4 Recreational vehicle sensor package instrument cluster. 1981-82 The recreational vehicle sensor package consists of a separate instrument cluster which allows the driver to monitor the following conditions: engine oil level, engine coolant level, transmission fluid level and transmission fluid temperature. TROUBLESHOOTING VOLTAGE LIMITER TEST 1. Connect voltmeter between temperature sending unit (locating in fitting in bottom radiator tank) and a suitable ground. Do not disconnect electrical connector from sending unit. 2. Turn ignition switch to On position and observe voltmeter. 3. If voltmeter needle fluctuates, the voltage limiter is operating properly. 4. If voltmeter does not fluctuate, replace voltage limiter. The voltage limiter is located on the sensor panel. To gain access to the limiter, remove panel and unsnap the back cover. TEMPERATURE GAUGE TEST 1. Disconnect electrical connector from temperature sending unit in lower radiator tank. 2. Connect tester No. C-3826 or equivalent between temperature sending unit and a suitable ground. 3. Move tester pointer to "C" position, then turn ignition switch On and observe temperature gauge. Temperature gauge should read within 1/8 inch of "C". 4. Move tester pointer to "M" position. Temperature gauge should now advance to normal range left of 1/2 position on dial. 5. Move tester pointer to "H" position. Temperature gauge should now advance to "H" position on dial. 6. If temperature gauge responds to tests described in steps 3, 4 and 5, but does not operate when sending unit electrical connector is attached, the sending unit is defective and should be replaced. 7. If temperature gauge does not respond to tests described in steps 3, 4 and 5, check for loose connections, broken wire, open printed circuit or faulty gauge. OIL LEVEL PUSH BUTTON SWITCH 1. Inspect switch for poor solder connections and repair or replace as necessary. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Testing and Inspection > Page 1043 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the switch should be replaced. To replace switch, remove circuit board and push switch toward back of sensor housing. PRINTED CIRCUIT BOARD 1. Inspect conductors for cracks or damaged circuits. 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the sensor panel assembly should be replaced. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair Oil Pan: Service and Repair V8-318 (5.2L), V8-360 (5.9L) & 446 (7.3L) 1. Drain engine oil and remove oil dipstick. 2. On 318 and 360 engines, disconnect crossover pipe from both manifolds. On Sport Utility vehicles, remove the left engine to transmission support only. 3. On all engines, remove the oil pan attaching screws and oil pan. 4. Reverse the procedure to install. Clean the oil pan in solvent and inspect the oil strainer alignment. On engines exc. V8-446 (7.3L), use a new pan gasket set and add a drop of sealant 4026070 or equivalent at corners of rubber and cork. On V8-446 (7.3L) engines, a liquid gasket material is used. Apply 1/8 inch bead of sealer at corners and both ends and 1/16 inch bead of sealer on both sides. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation CONSTANT VOLTAGE REGULATOR (CVR) TYPE This oil pressure indicating system incorporates an instrument voltage regulator, electrical oil pressure gauge and a sending unit which are connected in series. The sending unit consists of a diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm actuated the contact on the variable resistor, in turn controlling current flow to the gauge. When oil pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge, in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor is lowered, permitting an increased current flow to the gauge, resulting in an increased gauge reading. TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions included with the tester. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation > Page 1050 Oil Pressure Gauge: Testing and Inspection CONSTANT VOLTAGE REGULATOR (CVR) TYPE This oil pressure indicating system incorporates an instrument voltage regulator, electrical oil pressure gauge and a sending unit which are connected in series. The sending unit consists of a diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm actuated the contact on the variable resistor, in turn controlling current flow to the gauge. When oil pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge, in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor is lowered, permitting an increased current flow to the gauge, resulting in an increased gauge reading. TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions included with the tester. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Engine Mounted Switches & Sensors. Top Of Engine Applicable to: V8 Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation Many trucks utilize a warning light on the instrument panel in place of the conventional dash indicating gauge to warn the driver when the oil pressure is dangerously low. The warning light is wired in series with the ignition switch and the engine unit, which is an oil pressure switch. The oil pressure switch contains a diaphragm and a set of contacts. When the ignition switch is turned on, the warning light circuit is energized and the circuit is completed through the closed contacts in the pressure switch. When the engine is started, build-up of oil pressure compresses the diaphragm, opening the contacts, thereby breaking the circuit and putting out the light. TROUBLESHOOTING The oil pressure warning light should go on when the ignition is turned on. If it does not light, disconnect the wire from the engine unit and ground the wire to the frame or cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight and properly grounded, it should be removed and a new one installed. (The presence of sealing compound on the threads of the engine unit will cause a poor ground). If the warning light remains lit when it normally should be out, replace the engine unit before proceeding further to determine the cause for a low pressure indication. The warning light will sometimes light up or flicker when the engine is idling, even though the oil pressure is adequate. However, the light should go out when the engine speed is increased. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Page 1057 Oil Pressure Warning Lamp/Indicator: Testing and Inspection Many trucks utilize a warning light on the instrument panel in place of the conventional dash indicating gauge to warn the driver when the oil pressure is dangerously low. The warning light is wired in series with the ignition switch and the engine unit, which is an oil pressure switch. The oil pressure switch contains a diaphragm and a set of contacts. When the ignition switch is turned on, the warning light circuit is energized and the circuit is completed through the closed contacts in the pressure switch. When the engine is started, build-up of oil pressure compresses the diaphragm, opening the contacts, thereby breaking the circuit and putting out the light. TROUBLESHOOTING The oil pressure warning light should go on when the ignition is turned on. If it does not light, disconnect the wire from the engine unit and ground the wire to the frame or cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight and properly grounded, it should be removed and a new one installed. (The presence of sealing compound on the threads of the engine unit will cause a poor ground). If the warning light remains lit when it normally should be out, replace the engine unit before proceeding further to determine the cause for a low pressure indication. The warning light will sometimes light up or flicker when the engine is idling, even though the oil pressure is adequate. However, the light should go out when the engine speed is increased. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Specifications > Rebuild Specifications Oil Pump: Specifications Rotor Backlash 0.01 in Note: Maximum inner to outer rotor tip clearance. Rotor To Body Clearance 0.014 in Rotor End Play 0.001-0.004 in Note: Measured between pump cover mounting surface and end of gear, using straight edge and feeler gauge. Rotor Thickness(Height) Inner 0.825 in Outer 0.825 in Rotor Diameter 2.469 in Note: (Minimum) Cover Flatness Variation 0.0015 in Note: Maximum Relief Valve Spring Free Length 2.031 in Spring Pressure 16-17 lbf at 1.343 in Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Specifications > Rebuild Specifications > Page 1062 Oil Pump: Specifications Oil Pump Mounting Bolts 30 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Specifications > Page 1063 Oil Pump: Service and Repair Fig. 31 Oil pump. V8-318 (5.2L) & V8-360 (5.9L) Engine lubrication. V8-318 (5.2L) & V8-360 (5.9L) (Typical) V8-318 (5.2L) & V8-360 (5.9L) Removal of oil pump for servicing requires oil pan to be removed and oil pump unbolted from rear main bearing cap. With pump removed, disassemble pressure relief valve by pulling out cotter pins and drilling a 1/8 inch hole into center of relief valve retainer cap. Insert a self-threading sheet metal screw into cap and secure head in vise. While supporting pump body, remove cap by tapping body with soft hammer. Discard retainer cap and remove spring and relief valve. Relief valve spring has a free length of 2-1/32 to 2-3/64 inch and should test between 16.2 and 17.2 lbs. when compressed to 1-11/32 inch. Replace spring that fails to meet specifications. Unbolt oil pump cover and discard oil seal ring. Inner rotor and shaft can now be removed as well as outer rotor. Clean all parts thoroughly and inspect for damage or wear. If mating surface of oil pump cover is scratched or grooved, replace pump assembly. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Specifications > Page 1064 Fig. 25 Checking oil pump cover flatness. Typical Lay a straightedge across pump cover surface. If a .0015 inch feeler gauge can be inserted between cover and straightedge, replace pump assembly. Fig. 26 Measuring outer rotor thickness If outer rotor thickness measures 0.825 inch or less on 318 engine, or less than 0.943 inch on 360 engine, or the diameter is 2.469 inches or less, replace the outer rotor. Fig. 27 Measuring inner rotor thickness If inner rotor measures 0.825 inch or less on 318 engine or less than 0.943 on 360 engine, replace inner rotor and shaft assembly. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Specifications > Page 1065 Fig. 28 Measuring outer rotor clearance in pump body With outer rotor inserted into pump body, press rotor to one side with fingers. If clearance between rotor and pump body is .014 inch or more, replace oil pump assembly. Fig. 29 Measuring clearance over rotor With inner rotor inserted into pump body, place a straightedge across face between bolt holes. If a feeler gauge of 0.004 inch can be inserted between rotors and straightedge, replace oil pump assembly. Fig. 30 Measuring clearance between rotors Shaft and both rotors should be replaced if tip clearance between inner and outer rotor exceeds 0.010 inch. Using new parts as required, assemble pump. Prime pump before installation by filling rotor cavity with engine oil. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Specifications > Page 1066 Fig. 32 Oil pump. V8-446 (7.3L) Fig. 33 Measuring oil pump gear to body clearance. V8-446 (7.3L) V8-446 (7.3L) The oil pump consists of two gears and a pressure relief valve enclosed in the body. The pump is driven from the distributor drive gear. The body is equipped with a regulator valve that limits oil pressure to approximately 50 psi. After removing the oil pan, the pump may be removed from its mounting and disassembled for repairs. With the pump cover removed, exert pressure against gear with the thumb so as to push gear from outlet side of pump. Measure clearance between outside diameter of gear and bore of housing. If clearance is not between 0.0014 - 0.0054 inch, replace worn parts. Check pump shaft clearance in bore. If clearance is not between 0.001 - 0.0025 inch, replace pump. Check backlash between pump body and gears. If clearance is more than 0.0107 inch, replace gear. Check body gear end clearance. Clearance should be 0.0015 - 0.0065 inch. If endplay is not within specifications, add or remove oil pump cover gaskets to obtain specified clearance. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Intake Manifold 40 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1070 Intake Manifold: Service and Repair Fig. 2 Intake manifold tightening sequence. V8-318 (5.2L) & V8-360 (5.9L) V8-318 (5.2L) & V8-360 (5.9L) 1. Disconnect battery ground cable, then drain cooling system. 2. Remove alternator, carburetor air cleaner and fuel line, then disconnect accelerator linkage. 3. Remove vacuum control hose between carburetor and distributor. 4. Remove distributor cap with wires attached, then disconnect coil wires, heat indicator sending unit wire, heater hoses and bypass hose. 5. Remove closed ventilation system, evaporation control system and cylinder head covers. 6. Remove intake manifold attaching bolts, then the intake manifold. 7. Reverse procedure to install, noting the following: a. On V8-318 (5.2L) engines, coat intake manifold side gaskets with suitable sealer. b. On V8-360 (5.9L) engines, do not use any sealer on side composition gaskets. c. Apply a thin coating of suitable sealer to the intake manifold front and rear gaskets and cylinder block gasket surface. d. When installing front and rear gaskets, ensure center holes in gasket engage dowels in block and end holes in seals are locked into tangs of head gasket. e. Place a drop of suitable sealer onto each of the four manifold to cylinder head gasket corners. f. Tighten intake manifold bolts in sequence shown in Fig. 2. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Testing and Inspection Oil Level Warning Indicator: Testing and Inspection Remote Recreational Vehicle Sensor Package Fig. 3 Recreational vehicle sensor package instrument cluster. 1980 Fig. 4 Recreational vehicle sensor package instrument cluster. 1981-82 The recreational vehicle sensor package consists of a separate instrument cluster which allows the driver to monitor the following conditions: engine oil level, engine coolant level, transmission fluid level and transmission fluid temperature. TROUBLESHOOTING VOLTAGE LIMITER TEST 1. Connect voltmeter between temperature sending unit (locating in fitting in bottom radiator tank) and a suitable ground. Do not disconnect electrical connector from sending unit. 2. Turn ignition switch to On position and observe voltmeter. 3. If voltmeter needle fluctuates, the voltage limiter is operating properly. 4. If voltmeter does not fluctuate, replace voltage limiter. The voltage limiter is located on the sensor panel. To gain access to the limiter, remove panel and unsnap the back cover. TEMPERATURE GAUGE TEST 1. Disconnect electrical connector from temperature sending unit in lower radiator tank. 2. Connect tester No. C-3826 or equivalent between temperature sending unit and a suitable ground. 3. Move tester pointer to "C" position, then turn ignition switch On and observe temperature gauge. Temperature gauge should read within 1/8 inch of "C". 4. Move tester pointer to "M" position. Temperature gauge should now advance to normal range left of 1/2 position on dial. 5. Move tester pointer to "H" position. Temperature gauge should now advance to "H" position on dial. 6. If temperature gauge responds to tests described in steps 3, 4 and 5, but does not operate when sending unit electrical connector is attached, the sending unit is defective and should be replaced. 7. If temperature gauge does not respond to tests described in steps 3, 4 and 5, check for loose connections, broken wire, open printed circuit or faulty gauge. OIL LEVEL PUSH BUTTON SWITCH 1. Inspect switch for poor solder connections and repair or replace as necessary. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Testing and Inspection > Page 1075 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the switch should be replaced. To replace switch, remove circuit board and push switch toward back of sensor housing. PRINTED CIRCUIT BOARD 1. Inspect conductors for cracks or damaged circuits. 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the sensor panel assembly should be replaced. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation CONSTANT VOLTAGE REGULATOR (CVR) TYPE This oil pressure indicating system incorporates an instrument voltage regulator, electrical oil pressure gauge and a sending unit which are connected in series. The sending unit consists of a diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm actuated the contact on the variable resistor, in turn controlling current flow to the gauge. When oil pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge, in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor is lowered, permitting an increased current flow to the gauge, resulting in an increased gauge reading. TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions included with the tester. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation > Page 1079 Oil Pressure Gauge: Testing and Inspection CONSTANT VOLTAGE REGULATOR (CVR) TYPE This oil pressure indicating system incorporates an instrument voltage regulator, electrical oil pressure gauge and a sending unit which are connected in series. The sending unit consists of a diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm actuated the contact on the variable resistor, in turn controlling current flow to the gauge. When oil pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge, in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor is lowered, permitting an increased current flow to the gauge, resulting in an increased gauge reading. TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions included with the tester. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation Many trucks utilize a warning light on the instrument panel in place of the conventional dash indicating gauge to warn the driver when the oil pressure is dangerously low. The warning light is wired in series with the ignition switch and the engine unit, which is an oil pressure switch. The oil pressure switch contains a diaphragm and a set of contacts. When the ignition switch is turned on, the warning light circuit is energized and the circuit is completed through the closed contacts in the pressure switch. When the engine is started, build-up of oil pressure compresses the diaphragm, opening the contacts, thereby breaking the circuit and putting out the light. TROUBLESHOOTING The oil pressure warning light should go on when the ignition is turned on. If it does not light, disconnect the wire from the engine unit and ground the wire to the frame or cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight and properly grounded, it should be removed and a new one installed. (The presence of sealing compound on the threads of the engine unit will cause a poor ground). If the warning light remains lit when it normally should be out, replace the engine unit before proceeding further to determine the cause for a low pressure indication. The warning light will sometimes light up or flicker when the engine is idling, even though the oil pressure is adequate. However, the light should go out when the engine speed is increased. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Page 1083 Oil Pressure Warning Lamp/Indicator: Testing and Inspection Many trucks utilize a warning light on the instrument panel in place of the conventional dash indicating gauge to warn the driver when the oil pressure is dangerously low. The warning light is wired in series with the ignition switch and the engine unit, which is an oil pressure switch. The oil pressure switch contains a diaphragm and a set of contacts. When the ignition switch is turned on, the warning light circuit is energized and the circuit is completed through the closed contacts in the pressure switch. When the engine is started, build-up of oil pressure compresses the diaphragm, opening the contacts, thereby breaking the circuit and putting out the light. TROUBLESHOOTING The oil pressure warning light should go on when the ignition is turned on. If it does not light, disconnect the wire from the engine unit and ground the wire to the frame or cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight and properly grounded, it should be removed and a new one installed. (The presence of sealing compound on the threads of the engine unit will cause a poor ground). If the warning light remains lit when it normally should be out, replace the engine unit before proceeding further to determine the cause for a low pressure indication. The warning light will sometimes light up or flicker when the engine is idling, even though the oil pressure is adequate. However, the light should go out when the engine speed is increased. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Main Bearing Seal: > 091585 > Dec > 85 > Engine - Rear Crankshaft Seal Oil Leak Crankshaft Main Bearing Seal: Customer Interest Engine - Rear Crankshaft Seal Oil Leak Models 1984-1985 Passenger Car & Truck Equipped With 318 Engines Subject Crankshaft Rear Seal Leak Index ENGINE Date December 2, 1985 No. 09-15-85 P-4395-C SYMPTOM/CONDITION Oil leak at rear crankshaft (rope type) oil seal due to rotated upper oil seal. DIAGNOSIS Verify that the leak is at the rear crankshaft seal. REPAIR PROCEDURE This procedure insures that the protruded section of the seal is properly formed and has no frayed edges. 1. Remove oil pan. 2. Remove oil pump. 3. Remove rear crankshaft bearing cap. 4. Inspect upper seal half to see if it has rotated. Rotation of the seal will result in a gap at the right side of the main bearing cap and block parting line (Figure 1). If a gap is apparent, DO NOT REMOVE UPPER SEAL HALF. LEAVE IT IN THE BLOCK. 5. Remove the lower seal half from the main bearing cap. 6. Install the new lower seal half in the cap. Cut the right bank side flush with the cap surface. Remove the rope and rotate it so that the cut end protrudes above the surface the same amount it is short in the block half. Re-press the rope and cut the left bank side flush with the cap surface. 7. Lightly oil the lower seal half with engine oil. 8. Install the side seals making sure that the seal identified with yellow paint is installed on the right side. 9. Install the rear bearing cap, being careful not to crimp the long side of the oil seal between the cap and block. 10. Lightly oil, install, and torque the main bearing cap bolts to 85 foot pounds (115 N-m). 11. Reinstall the oil pump. 12. Reinstall the oil pan. 13. Check for oil leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Customer Interest for Crankshaft Main Bearing Seal: > 091585 > Dec > 85 > Engine - Rear Crankshaft Seal Oil Leak > Page 1093 TIME ALLOWANCE: Refer to Labor Operation Time Schedule for operation and time Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Main Bearing Seal: > 091585 > Dec > 85 > Engine - Rear Crankshaft Seal Oil Leak Crankshaft Main Bearing Seal: All Technical Service Bulletins Engine - Rear Crankshaft Seal Oil Leak Models 1984-1985 Passenger Car & Truck Equipped With 318 Engines Subject Crankshaft Rear Seal Leak Index ENGINE Date December 2, 1985 No. 09-15-85 P-4395-C SYMPTOM/CONDITION Oil leak at rear crankshaft (rope type) oil seal due to rotated upper oil seal. DIAGNOSIS Verify that the leak is at the rear crankshaft seal. REPAIR PROCEDURE This procedure insures that the protruded section of the seal is properly formed and has no frayed edges. 1. Remove oil pan. 2. Remove oil pump. 3. Remove rear crankshaft bearing cap. 4. Inspect upper seal half to see if it has rotated. Rotation of the seal will result in a gap at the right side of the main bearing cap and block parting line (Figure 1). If a gap is apparent, DO NOT REMOVE UPPER SEAL HALF. LEAVE IT IN THE BLOCK. 5. Remove the lower seal half from the main bearing cap. 6. Install the new lower seal half in the cap. Cut the right bank side flush with the cap surface. Remove the rope and rotate it so that the cut end protrudes above the surface the same amount it is short in the block half. Re-press the rope and cut the left bank side flush with the cap surface. 7. Lightly oil the lower seal half with engine oil. 8. Install the side seals making sure that the seal identified with yellow paint is installed on the right side. 9. Install the rear bearing cap, being careful not to crimp the long side of the oil seal between the cap and block. 10. Lightly oil, install, and torque the main bearing cap bolts to 85 foot pounds (115 N-m). 11. Reinstall the oil pump. 12. Reinstall the oil pan. 13. Check for oil leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Crankshaft Main Bearing Seal: > 091585 > Dec > 85 > Engine - Rear Crankshaft Seal Oil Leak > Page 1099 TIME ALLOWANCE: Refer to Labor Operation Time Schedule for operation and time Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Page 1100 Crankshaft Main Bearing Seal: Service and Repair Fig. 23 Rear main bearing caps. V8-318 (5.2L) & V8-360 (5.9L) V8-318 (5.2L) & V8-360 (5.9L) When necessary to replace rear main bearing oil seal on V8-318 models, removal of engine from vehicle or removal of crankshaft from engine block is not necessary. Remove engine oil pan as described under ``Oil Pan, Replace,'' then the rear main bearing cap. Using oil seal replacement tool No. KD-492 or equivalent, remove defective upper seal, then, using same tool, install new seal. After installation, trim upper seal to eliminate frayed ends. Install rear main bearing cap, then the oil pan as described under ``Oil Pan, Replace.'' Replacement of rear main bearing oil seals is similar to procedure given above for 6 cylinder engines. A seal retainer is not found on these engines; lower half of seal is installed into groove in rear main bearing cap. The 318 engine has cap seals in addition to lower seal secured by rear main bearing cap. Cap seal with yellow paint is installed, narrow sealing edge up, into right side with bearing cap in engine position. Cap seals must be flush with shoulder of bearing cap to prevent oil leakage. The 360 engine requires sealer to be applied adjacent to rear main bearing oil seal as cap seals are not used, Fig. 23. After applying sealer, quickly assemble rear main bearing cap to block and torque to specifications. V8-446 (7.3L) Crankshaft rear bearing oil seal consists of two pieces of special packing. One piece is installed in the groove in the rear bearing cap and the other piece is installed in a similar groove in the cylinder block. Position the rear bearing seal in the groove in the cylinder block. Lay an improvised mandrel in the bearing bore and strike the mandrel with a hammer to drive the seal into the groove. Install the seal in the bearing cap in a similar manner. Using a sharp knife, cut off both ends of each seal which project out of the grooves. When cutting off the ends of the seals, do not leave frayed ends which would prevent proper seating of the bearing cap if the ends should extend between cap and cylinder block. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Engine Mounted Switches & Sensors. Top Of Engine Applicable to: V8 Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Gear Bolt 35 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Chain & Sprockets Replacement Timing Chain: Service and Repair Timing Chain & Sprockets Replacement Fig. 14 Valve Timing. V8 Engines exc. V8-446 (7.3L) V8 ENGINES EXC. V8-446 (7.3L) To install chain and sprockets, lay both camshaft and crankshaft sprockets on bench. Position sprockets so that the timing marks are next to each other. Place chain on both sprockets, then push sprockets apart as far as the chain will permit. Use a straightedge to form a line through the exact centers of both gears. The timing marks must be on this line. Slide the chain with both sprockets on the camshaft and crankshaft at the same time, then recheck the alignment, Fig. 14. Use Tool C-3509 to prevent camshaft from contacting welch plug in rear of engine block. Remove distributor and oil pump distributor drive gear. Position tool against rear side of camshaft gear and attach with distributor retainer plate bolt. Fig. 15 Valve Timing. V8-446 (7.3L) V8-446 (7.3L) When valves are correctly timed, the timing marks on the gears or sprockets should be adjacent to each other, Fig. 15. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Chain & Sprockets Replacement > Page 1113 Timing Chain: Service and Repair Timing Chain Cover Replacement V8 ENGINES To remove cover, first drain cooling system, remove radiator, fan belt, power steering pump and water pump assembly. Then, remove pulley from vibration damper and after removing bolt and washer, use puller to remove damper. Next, remove fuel lines and fuel pump. Loosen oil pan bolts and after removing front bolt at each side, timing cover may be removed. Reverse procedure to install cover, using new oil seal. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair Timing Cover: Service and Repair V8 ENGINES To remove cover, first drain cooling system, remove radiator, fan belt, power steering pump and water pump assembly. Then, remove pulley from vibration damper and after removing bolt and washer, use puller to remove damper. Next, remove fuel lines and fuel pump. Loosen oil pan bolts and after removing front bolt at each side, timing cover may be removed. Reverse procedure to install cover, using new oil seal. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pump Pressure ............................................................................................................................ ........................................................ 4.75 psi - 6.25 psi Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package Technical Service Bulletin # 250485 Date: 850506 High Altitude Conversion Package Models 1985 Light Duty Domestic Trucks Subject High Altitude Conversion Packages & Adjustment for Improved Engine Performance Index EMISSIONS Date May 6, 1985 No.. 25-04-85 P-1522-C Packages are now available to accommodate a customer who wishes to convert his 1985 low altitude vehicle for improved high altitude (over 4,000 feet above sea level) engine performance. Vehicles with the low altitude package transferred to service in high altitude areas may exhibit undesirable driveability. However, the installation of a high altitude conversion package is voluntary and at the customer's expense. The high altitude field conversion packages and procedures outlined below have been authorized on the following 1985 non-altitude equipped engine families in service at altitudes above 4,000 feet above sea level. CONVERSION INSTRUCTIONS Sea Level to Altitude FIGURE 1 - Vehicle Emission Control Information Label IMPORTANT: IN SOME OF THE CONVERSION PROCEDURES YOU WILL BE REQUIRED TO INSTALL A NEW VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL PN 4275084. THIS LABEL HAS TWO AREAS THAT ARE IMPACT IMPRINTABLE WITH A TYPEWRITER (SEE FIGURE 1). If you are required to readjust timing, curb idle speed, or fast idle speed to a specification different than the original VECI label specification, then just type in the new specification after the subject operation. If you are asked to refer to the original VECI label specifications, type in on the right hand side of the label "Refer to Original VECI Label." Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1125 In every case where this label is used, type in after - AUTHORITY OF Technical Service Bulletin #25-04-85, and your dealer code below. Label PN 4275084 is available from Parts Supply. FIGURE 2 - Vehicle Emission Control Information Label The engine family chart below will help identify the appropriate parts to be installed by recording body style and engine family from the original VECI label. This chart cross references the EPA engine family with the engine application used in the accompanying instructions (refer to Figure 2). EPA Engine Family Engine Application (Found on VECI Label) 2.2L-2V Federal FCR2.2T2AAB6 2.2L-2V 50 States FCR2.2T2HBM9 2.6L-2V Federal FCR2.6T2AAB8 3.7L-1V Federal FCR3.7T1BBA0 5.2L-2V 50 States FCR5.2T2HBN1 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1126 5.2L-2V Federal FCR5.2T2BBF6 5.9L-4V Federal FCR5.9T4BBF1 POLICY: Information only 1985 2.2L-2V Light Duty Trucks All Models With Federal Emissions Package (49 States) Dodge Ram Van, Dodge Caravan, Plymouth Voy Consisting of: 1 - #211 Primary Main Jet PN 4293797 1 - #215 Secondary Main Jet PN 4240006 1 - #180 Primary High Speed Bleed PN 4342920 1 - #210 Secondary High Speed Bleed PN 4342921 1 - Carburetor Air Horn Gasket PN 4293846 INSTRUCTIONS FIGURE 1. Holley 5220 Primary Main Metering Jet #211 FIGURE 2. Holley 5220 Secondary Main Metering Jet #223 - Remove carburetor air horn. - Remove primary and secondary main metering jets. Refer to Figures 1 and 2. - Install #211 primary main metering jet PN 4293797. - Install #215 secondary main metering jet PN 4240006. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1127 FIGURE 3. Holley 5220 Primary High Speed Bleed #180 FIGURE 4. Holley 5220 Secondary High Speed Bleed #210 - Remove primary and secondary high speed bleeds. Refer to Figures 3 and 4. - Install #180 primary high speed bleed PN 4342920. - Install #210 secondary high speed bleed PN 4342921. FIGURE 5. Holley 5220 Power Valve Location - Turn power valve (Figure 5) two full turns counterclockwise (lean). - Reinstall air horn with new air horn gasket PN 4293846. Start engine and check for leaks. - Warm up engine and set idle speed to that specified on the VECI label. - Type in changes made on Emission Update Label PN 4275084 and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1128 1985 2.2L-2V Light Duty Truck Dodge Ram Van, Dodge Caravan & Plymouth Voyager Only Equipped With "50 States" Emission Package Consisting of: 1 - Carburetor (manual or automatic PN 4342891 transmission) Also order conversion hardware package. 1 - Hardware Package PN 4342950 Consisting of: 1 - Carburetor Base Gasket PN 4095975 1 - H.A.C. PN 4306202 1 - Hose Routing Diagram NPN 1 - Mounting Bracket (H.A.C.) PN 4105199 1 - H.A.C. Hose Harness NPN 3 - Mounting Screws NPN INSTRUCTIONS - Remove carburetor per instructions in appropriate engine performance/electrical shop manual. - Install new carburetor with new base gasket. FIGURE 6 - High Altitude Compensator Mounting - Install altitude compensator with bracket (Figure 6). - Install altitude compensator vacuum hose harness, route as shown in hose routing diagram (Figure 6). - Warm up engine. - Set engine idle speed to specified VECI label specification. - Set high fast idle on Step 3 (lowest) to specification. - Double check hose routing and installation of fuel lines. - Type in changes made on the Emission Update Label PN 4275084 and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1129 1985 2.6L-2V Light Duty Truck All Models With Federal Emissions Package (49 States) Consisting of: 1 - Carburetor Jet Kit PN MD088294 containing: #110 Primary Main Jet #175 Secondary Main Jet #100 Primary Air Bleed Jet #120 Secondary Air Bleed Jet 1 - Float Chamber Cover Gasket PN MD608639 1 - Choke Cover Screw Kit PN MD606977 1 - Carburetor Flange Gasket PN MD025344 INSTRUCTIONS - Remove carburetor from engine and take off air horn per instructions in appropriate service manual. FIGURE 7 - Mikuni Jet Locations - Remove primary and secondary main jets as shown in Figure 7. - Install #110 primary main jet and #175 secondary main jet in the primary and secondary pedestals. - Reinstall air horn on carburetor using new air horn gasket PN MD608639 and choke cover screw kit PN MD606977. FIGURE 8 - Mikuni Air Bleed Jet Locations - Remove primary and secondary air bleed jets shown in Figure 8. - Prepare carburetor for propane idle set by drilling out concealment plug. - Install #120 secondary air bleed jet and #100 primary air bleed jet. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1130 - Reinstall carburetor on engine using a new carburetor flange gasket, PN MD025344. - Remove vacuum controlled orificed tank vapor valve (VCOTV) and the vacuum/line(s) to the valve. - Remove the 3/16" tank vent line from the vapor canister and replace with 24" of 3/16" tank vent line and route directly to steel tank vent tube. - Remove the manifold vacuum line from the manifold vacuum tee (originally to the VCOTV) and cap the tee. - Remove the EGR delay valve at the corresponding EGR and carburetor ports and replace with 8" of bulk 3/16" vacuum line from stock. - Start engine and warm up to operating temperature. - Set idle rpm (curb) to 850 rpm and propane enriched rpm to 950 rpm. - Set throttle kicker rpm to 1050 rpm. FIGURE 9 - Authorized Modifications Label - Type in changes made on Authorized Modification Label, PN 4275086 (Figure 9), and affix to engine compartment next to VECI label. 1985 3.7L-1V Light Duty Trucks All Models With Federal Emission Package (49 States) Consisting of: 1 - #611 Main Metering Jet PN 3837520 1 - Carburetor Air Horn Gasket PN 4267140 INSTRUCTIONS - Remove carburetor. - Remove air horn from carburetor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1131 FIGURE 10 - Main Metering Jet Location - Remove existing main metering jet (Figure 10). - Install #611 main metering jet PN 3837520. - Reinstall air horn with new air horn gasket PN 4267140. - Drill out concealment plug and prepare carburetor for propane idle set. - Per instructions in appropriate service manual, perform a propane idle set. Reset the propane/curb idle speeds to 775/750 for manuals and 800/775 for automatics. - Reset HFI to 1600 on Step 2. - Reset choke vacuum kick to 0.120". - Reset idle solenoid speed to 850 rpm (manual transmission) or 875 (automatic transmission). - Type in changes made on Emission Update Label and affix in engine compartment next to VECI label. 1985 5.2L-2V Light Duty Trucks All Models With "50 States" Emissions Packages Consisting of: 1 - Carburetor PN 4306453 1 - EGR Valve PN 4094891 1 - EGR Valve Gasket PN 4287938 1 - Carburetor Gasket PN 4095970 INSTRUCTIONS Using procedures as outlined in the appropriate service manual, perform the following: - Remove existing carburetor. - Install replacement carburetor PN 4306453 and gasket. - Remove EGR valve and scrape off old gasket material. - Install replacement EGR valve PN 4094891 and new gasket PN 4287938. - Start engine and check for leaks. - Check and reset if necessary, curb idle, fast idle to VECI label specifications. - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1132 1985 5.2L-2V Light Duty Trucks All Models With Federal Emissions Package (49 States) Consisting of: 2 - Main Metering Jet #147 PN 4271983 1 - EGR Valve PN 4287678 1 - EGR Valve Gasket PN 4287938 1 - Carburetor Base Gasket PN 4095970 INSTRUCTIONS Per instructions in appropriate service manual, perform the following: - Remove carburetor from engine. - Remove air horn from carburetor. FIGURE 11 - Holley 2280 Main Metering Jets - Remove existing main metering jet (Figure 11). - Install main metering jets provided, PN 4271983. - Adjust vacuum kick to 0.150". - Adjust mechanical unloader to 0.280". - Remove EGR valve and scrape off old gasket material. - Install new EGR valve PN 4287678 with new gasket PN 4287938. - Start engine, check for leaks. - Prepare carburetor for propane idle set and reinstall on engine using gasket PN 4095970. - Start engine and check for leaks. - Perform propane idle adjustment to 700 rpm (curb idle) and 770 rpm (propane enriched idle). - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. 5.9L-4V Light Duty Trucks All Automatic Models With Federal Emissions Package Consisting of: 1 - Carburetor PN 4342807 1 - EGR Valve PN 4287659 1 - Carburetor Base Gasket PN 3698365 1 - EGR Valve Gasket PN 4287938 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1133 INSTRUCTIONS - Remove existing carburetor. - Install new carburetor PN 4342807 along with new carburetor base gasket PN 3698365. - Raise the rear wheels of the vehicle with the transmission in neutral. Rotate the rear wheels through one revolution and determine the axle ratio. - If the vehicle has a 3.55 or 4.10 axle, replace EGR valve with PN 4287659 and gasket PN 4287938. - Start engine and check for leaks. - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. 5.9L-4V Light Duty Trucks All Manual Models With Federal Emission Package Consisting of: 1 - Carburetor PN 4342807 1 - Carburetor Base Gasket PN 3698365 INSTRUCTIONS - Remove original carburetor. - Install replacement carburetor PN 4342807 using new base gasket PN 3698365. - Start engine and check for leaks. - Type in changes made on Emission Update Label PN 4275084 and affix to engine compartment next to original VECI label. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1134 Air/Fuel Mixture: Technical Service Bulletins Propane Idle Adjustment - Determination Guidelines Models 1985 Model Year Vehicles Subject Guidelines For Determining the Use of Idle Mixture Adjustment Index FUEL Date 10/1/84 No.. 14-46-84 P-4283C This bulletin should serve as a guideline to help determine when a propane or "CO" method idle set is to be performed. The propane or "CO" method idle mixture adjustment should only be performed if it is determined necessary by the propane or "CO" method idle check in the respective year Driveability Test Procedure books or service manual. More specifically, propane or "CO" method idle mixture adjustment should only be used if an idle "problem" still exists after normal diagnosis has revealed no other faulty condition such as incorrect idle speed, incorrect basic ignition timing, faulty hose, or wire connections, etc. It is also important to make sure the EFC/ESA combustion computer system is operating properly. Adjustment of the idle mixture should also be performed after a major carburetor overhaul. A guideline of conditions for determining whether a propane or "CO" method idle set is needed is attached. The conditions listed below are affected by idle mixture adjustment: ^ Rough Idle Warm ^ Breakaway Sag-Light Throttle Tip In ^ Decel Die Out ^ After a Major Carburetor Overhaul The conditions listed below are not affected by idle mixture adjustment: ^ Spark Knock ^ Poor Fuel Economy ^ Road Load Surge ^ Decel Bucking ^ Long Cold Crank ^ Cold Start Die Out Time ^ After-Run (dieseling) ^ Lack of Power on ^ Cold Rough Idle Acceleration POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Adjustments > Idle Mixture and Speed Adjustments Air/Fuel Mixture: Adjustments Idle Mixture and Speed Adjustments 1981-86: Disconnect and plug canister control and EGR vacuum hoses. Remove PCV valve from grommet and allow it to draw underhood air. With ESC, ground carb switch and disconnect Oxygen sensor. 1981-82: Set idle speed screw to specification. Set cam to specified step. Set fast idle. 1983-88, 6 & 8 cyl. models with solenoids.: Turn A/C on, set blower to low, disconnect compressor clutch wire. Without A/C, apply battery voltage to solenoid. Adjust speed-up solenoid by removing adjusting screw and spring and inserting a one-eighth inch allen wrench into socket and turning. Set idle speed by adjusting screw on carb body. 1987-88 4cyl.: Energize radiator fan with a jumper wire. Remove PCV valve from grommet and disconnect vacuum kicker solenoid electrical lead. Disconnect oxygen sensor test connector on left fender shield. Adjust idle speed screw on top of solenoid to specified idle speed. Place fast idle cam on specified step and adjust to specified value. Disconnect idle solenoid electrical lead and set base idle to specified value. Other models: Set idle speed by turning screw on carb body. Set cam to specified step and adjust fast idle to specification. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Adjustments > Idle Mixture and Speed Adjustments > Page 1137 Air/Fuel Mixture: Adjustments Idle Mixture (Propane Method) Fig. 1 Propane enrichment specification chart 1985 HOLLEY 6280 CARBURETOR This procedure should only be used after normal diagnosis has revealed no other faults, or if carburetor has been overhauled. Idle mixture adjustment requires artificial propane enrichment. A propane enrichment tool, C-4464 or equivalent, must be used to adjust idle mixture. Before proceeding, make sure that propane cylinder is adequately filled to ensure correct propane flow. 1. Remove concealment plug cap from mixture adjusting screw. Refer to appropriate carburetor section. 2. Set parking brake and place transmission in Neutral position. 3. Turn off all lights and accessories, then connect tachometer. 4. Start engine and allow to reach normal operating temperature, then turn off engine. 5. Disconnect and plug the vacuum hose at the EGR valve and ESA computer. 6. Disconnect and plug canister purge hose at canister. 7. Disconnect carburetor ground switch and ensure switch is not grounded. 8. Disconnect and ground oxygen sensor electrical connector. 9. start engine and allow to run for at least four minutes. 10. Disconnect vacuum supply hose from choke diaphragm at the carburetor, then install propane hose in its place. 11. Remove PCV valve from cylinder head and allow to draw in underhood air. Ensure that propane cylinder remains upright during procedure. 12. Open main propane valve fully. Slowly open propane metering valve until maximum idle RPM is obtained. Too much propane will cause engine speed to drop. Adjust metering valve to obtain maximum idle RPM. 13. With propane flowing, adjust idle speed to specified enriched RPM, Fig. 1, by turning idle speed screw. 14. Adjust metering valve to obtain maximum RPM. If there has been a change in maximum RPM, readjust idle speed screw to specified enriched RPM. 15. Turn off main propane valve and allow engine speed to stabilize. 16. Adjust mixture screws to obtain smoothest idle at specified curb idle RPM, allowing time between adjustments for engine speed to stabilize. 17. Turn on main propane valve and adjust metering valve to obtain maximum engine RPM. If maximum engine speed differs by more than 25 RPM from specified enriched RPM, repeat steps 12 through 17. 18. When adjustment is correct, turn off both propane valves, stop engine and remove tool. 19. Install new concealment plug, then connect oxygen sensor electrical connector. 20. Connect vacuum line at ESA, then perform ``Curb Idle Speed, Adjust'' and ``Fast Idle Speed, Adjust'' procedures. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package Technical Service Bulletin # 250485 Date: 850506 High Altitude Conversion Package Models 1985 Light Duty Domestic Trucks Subject High Altitude Conversion Packages & Adjustment for Improved Engine Performance Index EMISSIONS Date May 6, 1985 No.. 25-04-85 P-1522-C Packages are now available to accommodate a customer who wishes to convert his 1985 low altitude vehicle for improved high altitude (over 4,000 feet above sea level) engine performance. Vehicles with the low altitude package transferred to service in high altitude areas may exhibit undesirable driveability. However, the installation of a high altitude conversion package is voluntary and at the customer's expense. The high altitude field conversion packages and procedures outlined below have been authorized on the following 1985 non-altitude equipped engine families in service at altitudes above 4,000 feet above sea level. CONVERSION INSTRUCTIONS Sea Level to Altitude FIGURE 1 - Vehicle Emission Control Information Label IMPORTANT: IN SOME OF THE CONVERSION PROCEDURES YOU WILL BE REQUIRED TO INSTALL A NEW VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL PN 4275084. THIS LABEL HAS TWO AREAS THAT ARE IMPACT IMPRINTABLE WITH A TYPEWRITER (SEE FIGURE 1). If you are required to readjust timing, curb idle speed, or fast idle speed to a specification different than the original VECI label specification, then just type in the new specification after the subject operation. If you are asked to refer to the original VECI label specifications, type in on the right hand side of the label "Refer to Original VECI Label." Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1142 In every case where this label is used, type in after - AUTHORITY OF Technical Service Bulletin #25-04-85, and your dealer code below. Label PN 4275084 is available from Parts Supply. FIGURE 2 - Vehicle Emission Control Information Label The engine family chart below will help identify the appropriate parts to be installed by recording body style and engine family from the original VECI label. This chart cross references the EPA engine family with the engine application used in the accompanying instructions (refer to Figure 2). EPA Engine Family Engine Application (Found on VECI Label) 2.2L-2V Federal FCR2.2T2AAB6 2.2L-2V 50 States FCR2.2T2HBM9 2.6L-2V Federal FCR2.6T2AAB8 3.7L-1V Federal FCR3.7T1BBA0 5.2L-2V 50 States FCR5.2T2HBN1 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1143 5.2L-2V Federal FCR5.2T2BBF6 5.9L-4V Federal FCR5.9T4BBF1 POLICY: Information only 1985 2.2L-2V Light Duty Trucks All Models With Federal Emissions Package (49 States) Dodge Ram Van, Dodge Caravan, Plymouth Voy Consisting of: 1 - #211 Primary Main Jet PN 4293797 1 - #215 Secondary Main Jet PN 4240006 1 - #180 Primary High Speed Bleed PN 4342920 1 - #210 Secondary High Speed Bleed PN 4342921 1 - Carburetor Air Horn Gasket PN 4293846 INSTRUCTIONS FIGURE 1. Holley 5220 Primary Main Metering Jet #211 FIGURE 2. Holley 5220 Secondary Main Metering Jet #223 - Remove carburetor air horn. - Remove primary and secondary main metering jets. Refer to Figures 1 and 2. - Install #211 primary main metering jet PN 4293797. - Install #215 secondary main metering jet PN 4240006. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1144 FIGURE 3. Holley 5220 Primary High Speed Bleed #180 FIGURE 4. Holley 5220 Secondary High Speed Bleed #210 - Remove primary and secondary high speed bleeds. Refer to Figures 3 and 4. - Install #180 primary high speed bleed PN 4342920. - Install #210 secondary high speed bleed PN 4342921. FIGURE 5. Holley 5220 Power Valve Location - Turn power valve (Figure 5) two full turns counterclockwise (lean). - Reinstall air horn with new air horn gasket PN 4293846. Start engine and check for leaks. - Warm up engine and set idle speed to that specified on the VECI label. - Type in changes made on Emission Update Label PN 4275084 and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1145 1985 2.2L-2V Light Duty Truck Dodge Ram Van, Dodge Caravan & Plymouth Voyager Only Equipped With "50 States" Emission Package Consisting of: 1 - Carburetor (manual or automatic PN 4342891 transmission) Also order conversion hardware package. 1 - Hardware Package PN 4342950 Consisting of: 1 - Carburetor Base Gasket PN 4095975 1 - H.A.C. PN 4306202 1 - Hose Routing Diagram NPN 1 - Mounting Bracket (H.A.C.) PN 4105199 1 - H.A.C. Hose Harness NPN 3 - Mounting Screws NPN INSTRUCTIONS - Remove carburetor per instructions in appropriate engine performance/electrical shop manual. - Install new carburetor with new base gasket. FIGURE 6 - High Altitude Compensator Mounting - Install altitude compensator with bracket (Figure 6). - Install altitude compensator vacuum hose harness, route as shown in hose routing diagram (Figure 6). - Warm up engine. - Set engine idle speed to specified VECI label specification. - Set high fast idle on Step 3 (lowest) to specification. - Double check hose routing and installation of fuel lines. - Type in changes made on the Emission Update Label PN 4275084 and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1146 1985 2.6L-2V Light Duty Truck All Models With Federal Emissions Package (49 States) Consisting of: 1 - Carburetor Jet Kit PN MD088294 containing: #110 Primary Main Jet #175 Secondary Main Jet #100 Primary Air Bleed Jet #120 Secondary Air Bleed Jet 1 - Float Chamber Cover Gasket PN MD608639 1 - Choke Cover Screw Kit PN MD606977 1 - Carburetor Flange Gasket PN MD025344 INSTRUCTIONS - Remove carburetor from engine and take off air horn per instructions in appropriate service manual. FIGURE 7 - Mikuni Jet Locations - Remove primary and secondary main jets as shown in Figure 7. - Install #110 primary main jet and #175 secondary main jet in the primary and secondary pedestals. - Reinstall air horn on carburetor using new air horn gasket PN MD608639 and choke cover screw kit PN MD606977. FIGURE 8 - Mikuni Air Bleed Jet Locations - Remove primary and secondary air bleed jets shown in Figure 8. - Prepare carburetor for propane idle set by drilling out concealment plug. - Install #120 secondary air bleed jet and #100 primary air bleed jet. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1147 - Reinstall carburetor on engine using a new carburetor flange gasket, PN MD025344. - Remove vacuum controlled orificed tank vapor valve (VCOTV) and the vacuum/line(s) to the valve. - Remove the 3/16" tank vent line from the vapor canister and replace with 24" of 3/16" tank vent line and route directly to steel tank vent tube. - Remove the manifold vacuum line from the manifold vacuum tee (originally to the VCOTV) and cap the tee. - Remove the EGR delay valve at the corresponding EGR and carburetor ports and replace with 8" of bulk 3/16" vacuum line from stock. - Start engine and warm up to operating temperature. - Set idle rpm (curb) to 850 rpm and propane enriched rpm to 950 rpm. - Set throttle kicker rpm to 1050 rpm. FIGURE 9 - Authorized Modifications Label - Type in changes made on Authorized Modification Label, PN 4275086 (Figure 9), and affix to engine compartment next to VECI label. 1985 3.7L-1V Light Duty Trucks All Models With Federal Emission Package (49 States) Consisting of: 1 - #611 Main Metering Jet PN 3837520 1 - Carburetor Air Horn Gasket PN 4267140 INSTRUCTIONS - Remove carburetor. - Remove air horn from carburetor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1148 FIGURE 10 - Main Metering Jet Location - Remove existing main metering jet (Figure 10). - Install #611 main metering jet PN 3837520. - Reinstall air horn with new air horn gasket PN 4267140. - Drill out concealment plug and prepare carburetor for propane idle set. - Per instructions in appropriate service manual, perform a propane idle set. Reset the propane/curb idle speeds to 775/750 for manuals and 800/775 for automatics. - Reset HFI to 1600 on Step 2. - Reset choke vacuum kick to 0.120". - Reset idle solenoid speed to 850 rpm (manual transmission) or 875 (automatic transmission). - Type in changes made on Emission Update Label and affix in engine compartment next to VECI label. 1985 5.2L-2V Light Duty Trucks All Models With "50 States" Emissions Packages Consisting of: 1 - Carburetor PN 4306453 1 - EGR Valve PN 4094891 1 - EGR Valve Gasket PN 4287938 1 - Carburetor Gasket PN 4095970 INSTRUCTIONS Using procedures as outlined in the appropriate service manual, perform the following: - Remove existing carburetor. - Install replacement carburetor PN 4306453 and gasket. - Remove EGR valve and scrape off old gasket material. - Install replacement EGR valve PN 4094891 and new gasket PN 4287938. - Start engine and check for leaks. - Check and reset if necessary, curb idle, fast idle to VECI label specifications. - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1149 1985 5.2L-2V Light Duty Trucks All Models With Federal Emissions Package (49 States) Consisting of: 2 - Main Metering Jet #147 PN 4271983 1 - EGR Valve PN 4287678 1 - EGR Valve Gasket PN 4287938 1 - Carburetor Base Gasket PN 4095970 INSTRUCTIONS Per instructions in appropriate service manual, perform the following: - Remove carburetor from engine. - Remove air horn from carburetor. FIGURE 11 - Holley 2280 Main Metering Jets - Remove existing main metering jet (Figure 11). - Install main metering jets provided, PN 4271983. - Adjust vacuum kick to 0.150". - Adjust mechanical unloader to 0.280". - Remove EGR valve and scrape off old gasket material. - Install new EGR valve PN 4287678 with new gasket PN 4287938. - Start engine, check for leaks. - Prepare carburetor for propane idle set and reinstall on engine using gasket PN 4095970. - Start engine and check for leaks. - Perform propane idle adjustment to 700 rpm (curb idle) and 770 rpm (propane enriched idle). - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. 5.9L-4V Light Duty Trucks All Automatic Models With Federal Emissions Package Consisting of: 1 - Carburetor PN 4342807 1 - EGR Valve PN 4287659 1 - Carburetor Base Gasket PN 3698365 1 - EGR Valve Gasket PN 4287938 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1150 INSTRUCTIONS - Remove existing carburetor. - Install new carburetor PN 4342807 along with new carburetor base gasket PN 3698365. - Raise the rear wheels of the vehicle with the transmission in neutral. Rotate the rear wheels through one revolution and determine the axle ratio. - If the vehicle has a 3.55 or 4.10 axle, replace EGR valve with PN 4287659 and gasket PN 4287938. - Start engine and check for leaks. - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. 5.9L-4V Light Duty Trucks All Manual Models With Federal Emission Package Consisting of: 1 - Carburetor PN 4342807 1 - Carburetor Base Gasket PN 3698365 INSTRUCTIONS - Remove original carburetor. - Install replacement carburetor PN 4342807 using new base gasket PN 3698365. - Start engine and check for leaks. - Type in changes made on Emission Update Label PN 4275084 and affix to engine compartment next to original VECI label. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1151 Idle Speed: Technical Service Bulletins Propane Idle Adjustment - Determination Guidelines Models 1985 Model Year Vehicles Subject Guidelines For Determining the Use of Idle Mixture Adjustment Index FUEL Date 10/1/84 No.. 14-46-84 P-4283C This bulletin should serve as a guideline to help determine when a propane or "CO" method idle set is to be performed. The propane or "CO" method idle mixture adjustment should only be performed if it is determined necessary by the propane or "CO" method idle check in the respective year Driveability Test Procedure books or service manual. More specifically, propane or "CO" method idle mixture adjustment should only be used if an idle "problem" still exists after normal diagnosis has revealed no other faulty condition such as incorrect idle speed, incorrect basic ignition timing, faulty hose, or wire connections, etc. It is also important to make sure the EFC/ESA combustion computer system is operating properly. Adjustment of the idle mixture should also be performed after a major carburetor overhaul. A guideline of conditions for determining whether a propane or "CO" method idle set is needed is attached. The conditions listed below are affected by idle mixture adjustment: ^ Rough Idle Warm ^ Breakaway Sag-Light Throttle Tip In ^ Decel Die Out ^ After a Major Carburetor Overhaul The conditions listed below are not affected by idle mixture adjustment: ^ Spark Knock ^ Poor Fuel Economy ^ Road Load Surge ^ Decel Bucking ^ Long Cold Crank ^ Cold Start Die Out Time ^ After-Run (dieseling) ^ Lack of Power on ^ Cold Rough Idle Acceleration POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 1152 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Idle Mixture and Speed Adjustments Idle Speed: Adjustments Idle Mixture and Speed Adjustments 1981-86: Disconnect and plug canister control and EGR vacuum hoses. Remove PCV valve from grommet and allow it to draw underhood air. With ESC, ground carb switch and disconnect Oxygen sensor. 1981-82: Set idle speed screw to specification. Set cam to specified step. Set fast idle. 1983-88, 6 & 8 cyl. models with solenoids.: Turn A/C on, set blower to low, disconnect compressor clutch wire. Without A/C, apply battery voltage to solenoid. Adjust speed-up solenoid by removing adjusting screw and spring and inserting a one-eighth inch allen wrench into socket and turning. Set idle speed by adjusting screw on carb body. 1987-88 4cyl.: Energize radiator fan with a jumper wire. Remove PCV valve from grommet and disconnect vacuum kicker solenoid electrical lead. Disconnect oxygen sensor test connector on left fender shield. Adjust idle speed screw on top of solenoid to specified idle speed. Place fast idle cam on specified step and adjust to specified value. Disconnect idle solenoid electrical lead and set base idle to specified value. Other models: Set idle speed by turning screw on carb body. Set cam to specified step and adjust fast idle to specification. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Idle Mixture and Speed Adjustments > Page 1155 Idle Speed: Adjustments Idle Speed Adjustment Curb Idle Speed Adjustment 1. Disconnect and plug vacuum hose at EGR valve, ESA module, distributor or carburetor, as required. 2. On models equipped with carburetor ground switch, connect jumper wire between switch and ground. 3. On models not equipped with Spark Control Computer (SCC), disconnect and plug vacuum hose from carburetor at heated air temperature sensor and Orifice Spark Advance Control (OSAC) valve, if equipped. 4. On all models, disconnect and plug control hose at canister. 5. Remove PCV valve from cylinder head cover and allow to draw underhood air. 6. Connect tachometer, then start engine and allow to reach normal operating temperature. 7. On models less 1985 6280 carburetor, adjust Solenoid Idle Stop (SIS), if equipped, as follows: a. On 1983-84 models with A/C, turn on A/C and set blower on low, then disconnect A/C clutch wire. b. On 1983-84 models less A/C and all 1985-87 models, connect jumper wire between battery positive terminal and the SIS lead wire. Ensure correct jumper wire installation. Applying battery voltage to other than correct wire will damage the wiring harness. c. On all models, open throttle slightly to allow solenoid plunger to extend. d. On Holley models, remove adjusting screw and spring from solenoid, then insert 1/8 inch Allen wrench into the solenoid and adjust to correct engine RPM. e. On Carter models, turn adjusting screw on throttle lever to obtain correct engine RPM. f. On Rochester models, turn solenoid plunger screw to obtain correct engine RPM. g. Turn off A/C and reconnect clutch wire or remove jumper, if equipped. h. Install solenoid screw and spring, if equipped with Holley carburetor. 8. On models with 1985 6280 carburetor, adjust Solenoid Idle Stop (SIS) as follows: a. Disconnect and ground engine harness electrical connector from oxygen sensor. b. Allow engine to run at least five minutes, then connect a jumper wire between the battery positive terminal and SIS lead wire. Ensure correct jumper wire installation. Applying battery voltage to other than correct wire will damage the wiring harness. c. Open throttle slightly to allow solenoid plunger to extend. d. Remove adjusting screw and spring from solenoid, then insert a 1/8 inch allen wrench into the solenoid and adjust to correct engine RPM. e. Install screw and spring, then turn in screw until it bottoms out. 9. On 1983-84 models equipped with oxygen sensor feedback carburetors, proceed as follows: a. Disconnect electrical connector from oxygen sensor and ground connector. b. Remove and plug vacuum hose at vacuum transducer on SCC, then install suitable vacuum pump to vacuum transducer and apply 16 inches of vacuum. c. Allow engine to run for two minutes. If idle is not as specified, turn adjusting screw on solenoid to obtain correct RPM. 10. On 1983-84 models not equipped with oxygen sensor feedback carburetors and all 1985-87 model carburetors, proceed as follows: a. Allow engine to run for one minute. b. If idle RPM is not as specified, turn idle speed screw to obtain correct RPM. 11. On all models, turn off engine, connect vacuum lines and remove tachometer. Remove jumper wire and connect oxygen sensor electrical connector, if equipped. After step 11 has been completed, idle speed may change slightly. This condition is normal and engine speed should not be readjusted. Fast Idle Adjustment 1. Disconnect and plug vacuum hose at EGR valve, ESA computer and distributor, if equipped. 2. On models equipped with carburetor ground switch, connect jumper wire between switch and ground. 3. On models not equipped with Spark Control Computer (SCC), disconnect and plug vacuum hose from carburetor at heated air temperature sensor. 4. On all models, disconnect and plug control hose at canister. 5. Remove PCV valve from cylinder head cover and allow to draw underhood air. 6. Connect tachometer, then start engine and allow to reach normal operating temperature. 7. On models equipped with oxygen sensor feedback, disconnect electrical connector from oxygen sensor and ground connector, then allow engine to run for two minutes. 8. On models not equipped with oxygen sensor feedback, allow engine to run for one minute. 9. On all models, open throttle slightly and position fast idle adjusting screw on second highest step of fast idle cam. 10. Open choke fully, then adjust fast idle speed screw to obtain specified RPM. 11. Return to idle, then reposition adjusting screw on second highest step of fast idle cam to ensure correct RPM. Readjust if necessary. 12. Turn off engine, then connect vacuum hoses and remove tachometer. Remove jumper wire and connect oxygen sensor electrical connector, if equipped. After step 12 has been completed, idle speed may change slightly. This condition is normal and engine speed should not be readjusted. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1164 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1165 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1166 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1167 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1168 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1169 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1170 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1171 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1172 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1173 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1174 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1175 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1176 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1177 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1178 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1184 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1185 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1186 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1187 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1188 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1189 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1190 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1191 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1192 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1193 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1194 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1195 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1196 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1197 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1198 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Timing Marks and Indicators: Diagrams TIMING MARK 1981-85 5.2L & 5.9L Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams > Page 1209 TIMING MARK 1981-90 Some 5.2L & 5.9L Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair Ignition Cable: Service and Repair REMOVAL AND INSTALLATION Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (1/2 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. Engine Firing Order Install cables into the proper engine cylinder firing order. When replacing the spark plug and coil cables, route the cables correctly and secure in the proper retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also cause cross ignition of the plugs or short circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made between the plug cable and the distributor cap tower. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Vacuum Advance Unit <--> [Distributor Advance Unit] > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Vacuum Advance Unit <--> [Distributor Advance Unit] > Component Information > Specifications > Page 1217 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Vacuum Control > Component Information > Locations Distributor Vacuum Control: Locations Orifice Spark Advance Control (OSAC) Valve Location. In Air Cleaner Housing Applicable to: V8 Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Check Specifications Compression Check Specifications Compression Pressure 100 psi At cranking speed, engine temperature normalized, throttle Note: Minimum open Maximum Variation 25 psi Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments 1981-87 6-225 (3.7L) & ALL 1980-87 V8 ENGINES These engines are equipped with hydraulic lifters. No provision for adjustment is provided. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Removal Water Pump: Service and Repair Removal WATER PUMPS Water Pump Removal (1) Drain cooling system. If equipped with air-conditioning, remove radiator. (2) Loosen alternator adjusting strap bolt and pivot bolt. Loosen power steering and air pumps, if so equipped. Remove all drive belts. (3) On engines without air-conditioning remove alternator bracket attaching bolts from water pump. Swing alternator out of the way and tighten pivot bolt. (4) On engines with air-conditioning, remove alternator, adjusting bracket, and power steering pump attaching bolts and set aside. (5) Remove fan blade, spacer (or fluid unit), pulley and bolts as an assembly. CAUTION: To prevent silicone fluid from draining into fan drive bearing and ruining the lubricant, do not place drive unit with shaft pointing downward (if so equipped). (6) Disconnect heater and by-pass hoses. (7) Remove air-conditioning compressor pulley and field coil assembly. (8) Remove water pump-to-compressor front mount bracket bolts and bracket. (9) Remove pump retaining bolts and water pump assembly. Discard gasket and clean mating surfaces. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Removal > Page 1234 Water Pump: Service and Repair Installation Water Pump Installation (1) Install a new by-pass hose, if necessary, with clamp positioned in the center of the hose. (2) Install water pump using a new gasket. Tighten engine pump retainer bolts to 30 ft. lbs. (41 N.m). Rotate pump by hand to be sure it rotates freely. (3) Install heater hose and position by-pass hose clamps. (4) On engines without air-conditioning, install alternator front bracket and tighten to 30 ft. lbs. (41 N.m). (5) On engines with air-conditioning, install compressor front bracket. Tighten compressor bracket bolts to 50 ft. lbs. (68 N.m) and water pump retainer bolts to 30 ft. lbs. (41 N.m). Install alternator, adjusting bracket and power steering pump. Tighten all bolts to 30 ft. lbs. (41 N.m). Install compressor clutch assembly. (6) Install fan, spacer (or fluid unit), pulley and bolts as an assembly. (7) Install belts and adjust tension as described in belt tightening procedures. (8) Connect heater hose. Install radiator as outlined in this section. (9) Fill cooling system. See "Refilling Cooling System". Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Recycling Recommendations Coolant: Technical Service Bulletins Engine Coolant - Recycling Recommendations SUBJECT: Engine Coolant Recycling NO.: 07-03-90 GROUP: COOLING DATE: Dec. 21, 1990 MODELS: All Domestic & Import Vehicles DISCUSSION: A number of systems are being marketed to "recycle" or "reconstitute" used ethylene glycol antifreeze/coolant in the dealership. Some of the systems have been advertised as producing a recycled antifreeze "as good as" original and suggest the recycled product is suitable for use in Chrysler Corporation vehicles. Tests, so far, indicate most of these systems merely remove suspended solids from the used antifreeze/coolant through the use of various size filters. These systems do not remove glycol degradation products, or dissolved solids, which can cause water pump seal wear. These systems use a universal "reinhibitor package". The "reinhibitor package" can not restore every type antifreeze/coolant inhibitor system to a like new condition. Tests results indicate these "recycled" products do not consistently provide the protection required in Chrysler Corporation engines and cooling systems. The use of these "reconstituted" antifreeze/coolants is not authorized in the performance of any repair covered under the provisions of the warranty. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Page 1240 Coolant: Specifications MAKE, YEAR & MODEL LITERS QUARTS D, W Series Pickups 1993-91 3.9L V-6 14.0 15.1 5.2L V-8 16.0 17.0 5.9L V-8 Gas 14.7 15.5 5.9L I-6 Diesel: AT 16.1 17.0 MT 15.1 16.0 1990-88 3.9L V-6 14.0 15.1 5.2L V-8 16.0 17.0 5.9L V-8 Gas 14.5 15.5 5.9L I-6 Diesel: AT 15.7 16.5 MT 14.7 15.5 1987-83 3.7L I-6 11.5, 12.5* 12.0, 13.0* 5.2L V-8 15.0, 16.0* 16.0, 17.0* 5.9L V-8 13.5, 14.5* 14.5, 15.5* * Indicates with air conditioning Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Testing and Inspection Coolant Level Sensor: Testing and Inspection Recreational Vehicle (Coolant Level) Sensor Package Fig. 3 Recreational vehicle sensor package instrument cluster. 1980 Fig. 4 Recreational vehicle sensor package instrument cluster. 1981-82 The recreational vehicle sensor package consists of a separate instrument cluster which allows the driver to monitor the following conditions: engine oil level, engine coolant level, transmission fluid level and transmission fluid temperature. TROUBLESHOOTING VOLTAGE LIMITER TEST 1. Connect voltmeter between temperature sending unit (locating in fitting in bottom radiator tank) and a suitable ground. Do not disconnect electrical connector from sending unit. 2. Turn ignition switch to On position and observe voltmeter. 3. If voltmeter needle fluctuates, the voltage limiter is operating properly. 4. If voltmeter does not fluctuate, replace voltage limiter. The voltage limiter is located on the sensor panel. To gain access to the limiter, remove panel and unsnap the back cover. TEMPERATURE GAUGE TEST 1. Disconnect electrical connector from temperature sending unit in lower radiator tank. 2. Connect tester No. C-3826 or equivalent between temperature sending unit and a suitable ground. 3. Move tester pointer to "C" position, then turn ignition switch On and observe temperature gauge. Temperature gauge should read within 1/8 inch of "C". 4. Move tester pointer to "M" position. Temperature gauge should now advance to normal range left of 1/2 position on dial. 5. Move tester pointer to "H" position. Temperature gauge should now advance to "H" position on dial. 6. If temperature gauge responds to tests described in steps 3, 4 and 5, but does not operate when sending unit electrical connector is attached, the sending unit is defective and should be replaced. 7. If temperature gauge does not respond to tests described in steps 3, 4 and 5, check for loose connections, broken wire, open printed circuit or faulty gauge. OIL LEVEL PUSH BUTTON SWITCH 1. Inspect switch for poor solder connections and repair or replace as necessary. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Testing and Inspection > Page 1244 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the switch should be replaced. To replace switch, remove circuit board and push switch toward back of sensor housing. PRINTED CIRCUIT BOARD 1. Inspect conductors for cracks or damaged circuits. 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the sensor panel assembly should be replaced. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Description and Operation Fan Clutch: Description and Operation Fig. 1 Fan drive clutch assembly. 1984-87 models (1980-83 models similar) Fig. 2 Variable speed fan with coiled bimetallic thermostatic spring Do not operate engine until fan has first been inspected for cracks and/or separations. If a fan blade is found to be bent or damaged in any way, do not attempt to repair or reuse damaged part. Proper balance is essential in fan assembly operation. Balance cannot be assured once a fan assembly has been found to be bent or damaged and failure may occur during operation, creating an extremely dangerous condition. Always replace damaged fan assembly. The fan drive clutch is a fluid coupling containing silicone oil. Fan speed is regulated by the torque-carrying capacity of the silicone oil. The more silicone oil in the coupling, the greater the fan speed, and the less silicone oil, the slower the fan speed. The fan drive clutch uses a heat-sensitive, coiled bimetallic spring connected to an opening plate. This unit causes the fan speed to increase with a rise in temperature and to decrease as temperature decreases. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Description and Operation > Page 1249 Fan Clutch: Testing and Inspection Fig. 3 Bimetallic coiled spring removal FAN DRIVE CLUTCH TEST Do not operate the engine until the fan has been first checked for possible cracks and separations. To check the clutch fan, disconnect the bimetal spring and rotate 90° counterclockwise. This disables the temperature-controlled, free-wheeling feature and the clutch performs like a conventional fan. If this cures the overheating condition, replace the clutch fan. FAN CLUTCH NOISE Fan clutch noise can sometimes be noticed when clutch is engaged for maximum cooling. Clutch noise is also noticeable within the first few minutes after starting engine while clutch is redistributing the silicone fluid back to its normal, disengaged operating condition after settling for long periods of time (overnight). However, continuous fan noise or an excessive roar indicates the clutch assembly is locked-up due to internal failure. This condition can be checked by attempting to manually rotate fan. If fan cannot be rotated manually or there is a rough, abrasive feel as fan is rotated, the clutch should be replaced. FAN LOOSENESS Lateral movement can be observed at the fan blade tip under various temperature conditions because of the type bearing used. This movement should not exceed 1/4 inch (6.5 mm) as measured at the fan tip. If this lateral movement does not exceed specifications, there is no cause for replacement. CLUTCH FLUID LEAK Small fluid leaks do not generally affect the operation of the unit. These leaks generally occur around the area of the bearing assembly, but, if the leaks appear to be excessive, engine overheating may occur. Check for clutch and fan free-wheeling by attempting to rotate fan and clutch assembly by hand five times. If no drag is felt, replace clutch. FAN BLADE INSPECTION Place fan on flat surface with leading edge facing down. If there is a clearance between fan blade touching surface and opposite blade of more than 0.090 inch (2 mm), replace fan. (See caution at beginning of chapter.) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 1255 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations Coolant Temperature Sensor/Switch (For Computer): Component Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 1258 Coolant Temperature Sensor/Switch (For Computer): Connector Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 1259 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Coolant Temperature Switch Coolant Temperature Sensor/Switch (For Computer): Description and Operation Coolant Temperature Switch Fig. 4 Switches & sensors location. V8 engine On V8 engines the coolant switch is located on the front of the intake manifold, Fig. 4. It operates by supplying a signal to the computer when the engine coolant temperature is below 150~ F. This information is required to prevent a change in air fuel ratio until engine operation temperature is reached except there is no control of canister purging. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Coolant Temperature Switch > Page 1262 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Description The coolant temperature sensor measures temperature of the engine coolant. The coolant temperature sensor is mounted in the thermostat housing or in water passage of intake manifold. The sensor monitors engine coolant (operating) temperature. It supplies the logic module with a voltage signal which varies with coolant temperature. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations Temperature Sensor (Gauge): Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair Heater Core: Service and Repair Fig. 17 Heater assembly. Ramcharger, Trail Duster & Conventional Cabs less A/C. 1981-84 shown, 1985-87 similar 1981-87 Models 1. Disconnect battery ground cable. 2. Disconnect heater hoses on engine side and plug heater outlets. 3. Remove right side cowl trim if so equipped. 4. Remove glove box, then structural brace through glove box opening. 5. Remove right half of instrument panel lower reinforcement, making sure to disconnect ground strap. 6. Disconnect control cables, then blower motor wires on engine side. 7. Disconnect wires from resistor block. 8. Remove screw holding heater to cowl side sheet metal. 9. Remove 6 heater retaining nuts on firewall, then remove heater. 10. Remove mode door crank and 15 screws to remove cover from housing, then slide heater core out. 11. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Page 1269 Fig. 19 Heater assembly. 1981 Trail Duster & 1981-87 Ramcharger & Conventional Cabs. With A/C 1981-87 Models 1. Disconnect battery ground cable. 2. Discharge A/C system and disconnect refrigerant and heater lines from unit. 3. Move shift levers away from dash. 4. Remove right side cowl trim panel, if equipped. 5. Remove 4 screws at base and remove glove box. 6. Remove brace through glove box opening and remove ashtray. 7. Remove right half of lower reinforcement (7 screws to instrument panel and 1 to cowl side of trim panel). 8. Disconnect radio ground strap. 9. Remove right upper air duct by removing mounting screw and pulling duct out through glove box opening. 10. Remove instrument panel center brace and right instrument panel cluster pivot bolt. 11. Remove instrument panel cluster, disconnect shift indicator cable and lower steering column. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Page 1270 12. Remove steering column studs and radio. 13. Remove scoop connecting heater to center distribution duct (2 screws). 14. Remove center distribution duct by pulling bottom of dash out to gain clearance. 15. Remove floor air distribution duct. 16. Disconnect temperature control cable through glove box. 17. Remove 7 retaining nuts from firewall and screw that retains assembly to cowl side sheet metal. 18. Flex dash out and remove heater assembly. 19. Remove nuts from door arms and remove door arms. 20. Remove 7 screws to remove cover from housing. 21. Remove evaporator core. 22. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts Technical Service Bulletin # 181986 Date: 860210 Choke - Hard Hot Restarts Models All 1985-1986 Cars & Trucks Equipped With Quadrajet 4-BBL Carburetors (318-360) Subject Premature Choke Closing Causing Hard Hot Restarts Index DRIVEABILITY Date February 10, 1986 No. 18-19-86 P-362-C Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Partial choke closure which results in a rich condition causing hard worm and hard hot starts in cool or cold ambients. The vehicle may exhibit block smoke out the tailpipe for the first few miles of driving. DIAGNOSIS Remove the air cleaner and visually verify the choke blade is closing when the engine is worm or hot while the ambient is cool or cold. PARTS REQUIRED For 318 4BBL Passenger Cars and 318/360 4BBL D and W Trucks Driveability PN 4397683 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose (Preformed) PN 4361146 1 Heater Hose PN 3849197 1 Screw PN 3730000 "M" body cars will require the following to be ordered separately: 1 Water Valve PN 4085474 3 Tie Wraps PN 6015756 For 318 4BBL Police Vehicles With Silicone Hoses Only Driveability Package PN 4397684 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose (Preformed Silicone) PN 3849564 1 Heater Hose Silicone PN 3849472 1 Water Valve PN 4085474 1 Screw PN 3730000 3 Tie Wraps PN 6015756 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 1279 For 318 4BBL/360 4BBL "B" Model Vans Driveability Package PN 4397685 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose PN 4361142 3 Tie Wraps PN 6015756 1 Screw PN 3730000 To be ordered separately for all vehicles: 1 Authorized Modification Label PN 4275086 Repair Procedures This repair procedure involves the routing of the heater supply hose so it contacts the choke housing. The heat from this hose reduces the tendency of the choke to close before the engine cools off. It is, therefore, very important the heater hose be in direct contact with the choke housing. "M" Body Passenger Cars and D-W Series Trucks Without Silicone Heater Hoses and With Air Conditioning 1. Remove and discard the supply heater hoses and the water control valve. This is the hose that connects the intake manifold to the heater core. 2. Remove the return heater hose from the heater core at the cowl and install it on the opposite nipple of the heater core. 3. Remove and discard 33 inches off the straight end of the preformed hose, PN 4361146. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 1280 FIGURE 2 4. Clamp water valve, PN 4085474, onto the straight end of heater hose, PN 4361146, which was cut off in Step 3 above. This water valve has an embossed arrow on it to indicate water flow. This arrow must point toward the heater core or precise control of water flow to the heater will be impossible. Proper orientation of this valve is illustrated in Figure 2. Install heater hose, PN 3849197, on the other side of the water valve. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 1281 FIGURE 1 5. Attach supply heater hose bracket, PN 4307576, to the intake manifold boss using enclosed screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 1282 FIGURE 3 6. Install the 90~ bend of the supply heater hose and valve assembly onto the nipple on intake manifold. Route the supply hose past the carburetor choke housing and install the straight end of the hose onto the heater core inlet nipple. Install heater hose onto bracket and clamp securely in place (see Figure 3). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 1283 FIGURE 6 7. Attach Authorization Modification Label, PN 4275086, as illustrated in Figure 6. "M" Body Police With Silicone Heater Hoses 1. Follow the same installation procedure as on "M" body passenger car except silicone heater hose, PN 3849564, must be substituted for passenger car hose, PN 4361146. Silicone heater hose, PN 3849472, must be substituted for passenger car heater hose, PN 3849197. FIGURE 6 2. Attach Authorization Modification Label, PN 4274086, as illustrated in Figure 6. D and W Model Trucks Without Air Conditioning 1. Remove and discard the supply heater hose that connects the intake manifold to the heater core. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 1284 FIGURE 1 2. Attach heater hose bracket to intake manifold boss using screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 1285 FIGURE 5 3. Install 90~ bend of heater supply hose, PN 4361146, onto the intake manifold nipple. Route this hose post carburetor choke housing and install straight end of hose on the heater core nipple. Install hose into bracket and clump hose securely in place (see Figure 5). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 1286 FIGURE 6 4. Attach Authorization Modification Label, PN 4274086, as illustrated in Figure 6. "B" Model Van With and Without Air Conditioning 1. Remove and discard supply heater hose that connects the intake manifold to the heater core or to the water valve, if the vehicle is air conditioning equipped. FIGURE 1 2. Attach heater hose bracket, PN 4307576, to intake manifold boss using screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 1287 3. Install 90~ end of supply heater hose, PN 4361142, onto the intake manifold nipple. Route this heater supply hose post the carburetor choke housing and install the straight end on the heater core or on the water valve, if the vehicle has air conditioning. This hose must be cut to length as required. Install this heater supply hose into the hose bracket previously attached to the intake manifold. FIGURE 4 4. Using tie wraps, PN 6015756, secure supply heater hose to automatic transmission dip stick tube. Use caution as not to deform dip stick tube, as this will make transmission fluid level checks difficult or impossible. Using tie wraps, tie the supply and return heater hoses together as illustrated in Figure 4. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 1288 FIGURE 6 5. Attach Authorization Modification Label, PN 4275086, as illustrated in Figure 6. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 14-30-56-96 Premature Choke Closing "B" Van 0.7 Hrs. D-W Truck and "M" Body Passenger Car 0.5 Hrs. 14-30-56-97 Optional Equipment Air Conditioning "B" Van 0.3 Hrs. D-W Truck and "M" Body Passenger Car 0.4 Hrs. FAILURE CODE: AM - Authorized Modification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 1289 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts Technical Service Bulletin # 181986 Date: 860210 Choke - Hard Hot Restarts Models All 1985-1986 Cars & Trucks Equipped With Quadrajet 4-BBL Carburetors (318-360) Subject Premature Choke Closing Causing Hard Hot Restarts Index DRIVEABILITY Date February 10, 1986 No. 18-19-86 P-362-C Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Partial choke closure which results in a rich condition causing hard worm and hard hot starts in cool or cold ambients. The vehicle may exhibit block smoke out the tailpipe for the first few miles of driving. DIAGNOSIS Remove the air cleaner and visually verify the choke blade is closing when the engine is worm or hot while the ambient is cool or cold. PARTS REQUIRED For 318 4BBL Passenger Cars and 318/360 4BBL D and W Trucks Driveability PN 4397683 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose (Preformed) PN 4361146 1 Heater Hose PN 3849197 1 Screw PN 3730000 "M" body cars will require the following to be ordered separately: 1 Water Valve PN 4085474 3 Tie Wraps PN 6015756 For 318 4BBL Police Vehicles With Silicone Hoses Only Driveability Package PN 4397684 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose (Preformed Silicone) PN 3849564 1 Heater Hose Silicone PN 3849472 1 Water Valve PN 4085474 1 Screw PN 3730000 3 Tie Wraps PN 6015756 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 1295 For 318 4BBL/360 4BBL "B" Model Vans Driveability Package PN 4397685 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose PN 4361142 3 Tie Wraps PN 6015756 1 Screw PN 3730000 To be ordered separately for all vehicles: 1 Authorized Modification Label PN 4275086 Repair Procedures This repair procedure involves the routing of the heater supply hose so it contacts the choke housing. The heat from this hose reduces the tendency of the choke to close before the engine cools off. It is, therefore, very important the heater hose be in direct contact with the choke housing. "M" Body Passenger Cars and D-W Series Trucks Without Silicone Heater Hoses and With Air Conditioning 1. Remove and discard the supply heater hoses and the water control valve. This is the hose that connects the intake manifold to the heater core. 2. Remove the return heater hose from the heater core at the cowl and install it on the opposite nipple of the heater core. 3. Remove and discard 33 inches off the straight end of the preformed hose, PN 4361146. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 1296 FIGURE 2 4. Clamp water valve, PN 4085474, onto the straight end of heater hose, PN 4361146, which was cut off in Step 3 above. This water valve has an embossed arrow on it to indicate water flow. This arrow must point toward the heater core or precise control of water flow to the heater will be impossible. Proper orientation of this valve is illustrated in Figure 2. Install heater hose, PN 3849197, on the other side of the water valve. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 1297 FIGURE 1 5. Attach supply heater hose bracket, PN 4307576, to the intake manifold boss using enclosed screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 1298 FIGURE 3 6. Install the 90~ bend of the supply heater hose and valve assembly onto the nipple on intake manifold. Route the supply hose past the carburetor choke housing and install the straight end of the hose onto the heater core inlet nipple. Install heater hose onto bracket and clamp securely in place (see Figure 3). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 1299 FIGURE 6 7. Attach Authorization Modification Label, PN 4275086, as illustrated in Figure 6. "M" Body Police With Silicone Heater Hoses 1. Follow the same installation procedure as on "M" body passenger car except silicone heater hose, PN 3849564, must be substituted for passenger car hose, PN 4361146. Silicone heater hose, PN 3849472, must be substituted for passenger car heater hose, PN 3849197. FIGURE 6 2. Attach Authorization Modification Label, PN 4274086, as illustrated in Figure 6. D and W Model Trucks Without Air Conditioning 1. Remove and discard the supply heater hose that connects the intake manifold to the heater core. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 1300 FIGURE 1 2. Attach heater hose bracket to intake manifold boss using screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 1301 FIGURE 5 3. Install 90~ bend of heater supply hose, PN 4361146, onto the intake manifold nipple. Route this hose post carburetor choke housing and install straight end of hose on the heater core nipple. Install hose into bracket and clump hose securely in place (see Figure 5). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 1302 FIGURE 6 4. Attach Authorization Modification Label, PN 4274086, as illustrated in Figure 6. "B" Model Van With and Without Air Conditioning 1. Remove and discard supply heater hose that connects the intake manifold to the heater core or to the water valve, if the vehicle is air conditioning equipped. FIGURE 1 2. Attach heater hose bracket, PN 4307576, to intake manifold boss using screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 1303 3. Install 90~ end of supply heater hose, PN 4361142, onto the intake manifold nipple. Route this heater supply hose post the carburetor choke housing and install the straight end on the heater core or on the water valve, if the vehicle has air conditioning. This hose must be cut to length as required. Install this heater supply hose into the hose bracket previously attached to the intake manifold. FIGURE 4 4. Using tie wraps, PN 6015756, secure supply heater hose to automatic transmission dip stick tube. Use caution as not to deform dip stick tube, as this will make transmission fluid level checks difficult or impossible. Using tie wraps, tie the supply and return heater hoses together as illustrated in Figure 4. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 1304 FIGURE 6 5. Attach Authorization Modification Label, PN 4275086, as illustrated in Figure 6. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 14-30-56-96 Premature Choke Closing "B" Van 0.7 Hrs. D-W Truck and "M" Body Passenger Car 0.5 Hrs. 14-30-56-97 Optional Equipment Air Conditioning "B" Van 0.3 Hrs. D-W Truck and "M" Body Passenger Car 0.4 Hrs. FAILURE CODE: AM - Authorized Modification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 1305 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation Temperature Warning Lamp/Indicator: Description and Operation A bimetal temperature switch located in the cylinder head controls the operation of a temperature indicator light with a red lens. If the engine cooling system is not functioning properly and coolant temperature exceeds a predetermined value, the warning light will illuminate. TROUBLESHOOTING If the red light is not lit when the engine is being cranked, check for a burned out bulb, an open in the light circuit, or a defective ignition switch. If the red light is lit when the engine is running, check the wiring between light and switch for a ground, defective temperature switch, or overheated cooling system. As a test circuit to check whether the red bulb is functioning properly, a wire which is connected to the ground terminal of the ignition switch is tapped into its circuit. When the ignition is in the "Start" (engine cranking) position, the ground terminal is grounded inside the switch and the red bulb will be lit. When the engine is started and the ignition switch is in the "On" position, the test circuit is opened and the bulb is then controlled by the temperature switch. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation > Page 1310 Temperature Warning Lamp/Indicator: Testing and Inspection A bimetal temperature switch, located in the cylinder head, controls the operation of a temperature indicator light with a red lens. If the engine cooling system is not functioning properly and coolant temperature exceeds a predetermined value, the warning light will illuminate. TROUBLESHOOTING If the red light is not lit when the engine is being cranked, check for a burned out bulb, an open in the light circuit, or a defective ignition switch. If the red light is lit when the engine is running, check the wiring between light and switch for a ground, defective temperature switch, or overheated cooling system. As a test circuit to check whether the red bulb is functioning properly, a wire which is connected to the ground terminal of the ignition switch is tapped into its circuit. When the ignition is in the "Start" (engine cranking) position, the ground terminal is grounded inside the switch and the red bulb will be lit. When the engine is started and the ignition switch is in the "On" position, the test circuit is opened and the bulb is then controlled by the temperature switch. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Testing and Inspection Coolant Level Sensor: Testing and Inspection Recreational Vehicle (Coolant Level) Sensor Package Fig. 3 Recreational vehicle sensor package instrument cluster. 1980 Fig. 4 Recreational vehicle sensor package instrument cluster. 1981-82 The recreational vehicle sensor package consists of a separate instrument cluster which allows the driver to monitor the following conditions: engine oil level, engine coolant level, transmission fluid level and transmission fluid temperature. TROUBLESHOOTING VOLTAGE LIMITER TEST 1. Connect voltmeter between temperature sending unit (locating in fitting in bottom radiator tank) and a suitable ground. Do not disconnect electrical connector from sending unit. 2. Turn ignition switch to On position and observe voltmeter. 3. If voltmeter needle fluctuates, the voltage limiter is operating properly. 4. If voltmeter does not fluctuate, replace voltage limiter. The voltage limiter is located on the sensor panel. To gain access to the limiter, remove panel and unsnap the back cover. TEMPERATURE GAUGE TEST 1. Disconnect electrical connector from temperature sending unit in lower radiator tank. 2. Connect tester No. C-3826 or equivalent between temperature sending unit and a suitable ground. 3. Move tester pointer to "C" position, then turn ignition switch On and observe temperature gauge. Temperature gauge should read within 1/8 inch of "C". 4. Move tester pointer to "M" position. Temperature gauge should now advance to normal range left of 1/2 position on dial. 5. Move tester pointer to "H" position. Temperature gauge should now advance to "H" position on dial. 6. If temperature gauge responds to tests described in steps 3, 4 and 5, but does not operate when sending unit electrical connector is attached, the sending unit is defective and should be replaced. 7. If temperature gauge does not respond to tests described in steps 3, 4 and 5, check for loose connections, broken wire, open printed circuit or faulty gauge. OIL LEVEL PUSH BUTTON SWITCH 1. Inspect switch for poor solder connections and repair or replace as necessary. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Testing and Inspection > Page 1315 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the switch should be replaced. To replace switch, remove circuit board and push switch toward back of sensor housing. PRINTED CIRCUIT BOARD 1. Inspect conductors for cracks or damaged circuits. 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the sensor panel assembly should be replaced. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 1321 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations Coolant Temperature Sensor/Switch (For Computer): Component Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 1324 Coolant Temperature Sensor/Switch (For Computer): Connector Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 1325 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Coolant Temperature Switch Coolant Temperature Sensor/Switch (For Computer): Description and Operation Coolant Temperature Switch Fig. 4 Switches & sensors location. V8 engine On V8 engines the coolant switch is located on the front of the intake manifold, Fig. 4. It operates by supplying a signal to the computer when the engine coolant temperature is below 150~ F. This information is required to prevent a change in air fuel ratio until engine operation temperature is reached except there is no control of canister purging. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Coolant Temperature Switch > Page 1328 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Description The coolant temperature sensor measures temperature of the engine coolant. The coolant temperature sensor is mounted in the thermostat housing or in water passage of intake manifold. The sensor monitors engine coolant (operating) temperature. It supplies the logic module with a voltage signal which varies with coolant temperature. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Locations Temperature Sensor (Gauge): Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation Temperature Warning Lamp/Indicator: Description and Operation A bimetal temperature switch located in the cylinder head controls the operation of a temperature indicator light with a red lens. If the engine cooling system is not functioning properly and coolant temperature exceeds a predetermined value, the warning light will illuminate. TROUBLESHOOTING If the red light is not lit when the engine is being cranked, check for a burned out bulb, an open in the light circuit, or a defective ignition switch. If the red light is lit when the engine is running, check the wiring between light and switch for a ground, defective temperature switch, or overheated cooling system. As a test circuit to check whether the red bulb is functioning properly, a wire which is connected to the ground terminal of the ignition switch is tapped into its circuit. When the ignition is in the "Start" (engine cranking) position, the ground terminal is grounded inside the switch and the red bulb will be lit. When the engine is started and the ignition switch is in the "On" position, the test circuit is opened and the bulb is then controlled by the temperature switch. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation > Page 1335 Temperature Warning Lamp/Indicator: Testing and Inspection A bimetal temperature switch, located in the cylinder head, controls the operation of a temperature indicator light with a red lens. If the engine cooling system is not functioning properly and coolant temperature exceeds a predetermined value, the warning light will illuminate. TROUBLESHOOTING If the red light is not lit when the engine is being cranked, check for a burned out bulb, an open in the light circuit, or a defective ignition switch. If the red light is lit when the engine is running, check the wiring between light and switch for a ground, defective temperature switch, or overheated cooling system. As a test circuit to check whether the red bulb is functioning properly, a wire which is connected to the ground terminal of the ignition switch is tapped into its circuit. When the ignition is in the "Start" (engine cranking) position, the ground terminal is grounded inside the switch and the red bulb will be lit. When the engine is started and the ignition switch is in the "On" position, the test circuit is opened and the bulb is then controlled by the temperature switch. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Removal Water Pump: Service and Repair Removal WATER PUMPS Water Pump Removal (1) Drain cooling system. If equipped with air-conditioning, remove radiator. (2) Loosen alternator adjusting strap bolt and pivot bolt. Loosen power steering and air pumps, if so equipped. Remove all drive belts. (3) On engines without air-conditioning remove alternator bracket attaching bolts from water pump. Swing alternator out of the way and tighten pivot bolt. (4) On engines with air-conditioning, remove alternator, adjusting bracket, and power steering pump attaching bolts and set aside. (5) Remove fan blade, spacer (or fluid unit), pulley and bolts as an assembly. CAUTION: To prevent silicone fluid from draining into fan drive bearing and ruining the lubricant, do not place drive unit with shaft pointing downward (if so equipped). (6) Disconnect heater and by-pass hoses. (7) Remove air-conditioning compressor pulley and field coil assembly. (8) Remove water pump-to-compressor front mount bracket bolts and bracket. (9) Remove pump retaining bolts and water pump assembly. Discard gasket and clean mating surfaces. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Removal > Page 1340 Water Pump: Service and Repair Installation Water Pump Installation (1) Install a new by-pass hose, if necessary, with clamp positioned in the center of the hose. (2) Install water pump using a new gasket. Tighten engine pump retainer bolts to 30 ft. lbs. (41 N.m). Rotate pump by hand to be sure it rotates freely. (3) Install heater hose and position by-pass hose clamps. (4) On engines without air-conditioning, install alternator front bracket and tighten to 30 ft. lbs. (41 N.m). (5) On engines with air-conditioning, install compressor front bracket. Tighten compressor bracket bolts to 50 ft. lbs. (68 N.m) and water pump retainer bolts to 30 ft. lbs. (41 N.m). Install alternator, adjusting bracket and power steering pump. Tighten all bolts to 30 ft. lbs. (41 N.m). Install compressor clutch assembly. (6) Install fan, spacer (or fluid unit), pulley and bolts as an assembly. (7) Install belts and adjust tension as described in belt tightening procedures. (8) Connect heater hose. Install radiator as outlined in this section. (9) Fill cooling system. See "Refilling Cooling System". Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation The dual catalytic converters used on 6 cylinder and V8 engines, decrease HC and CO emissions or NOx emissions, or all three of these exhaust pollutants. The converters used in this system are tandem mounted. Oxidation Catalyst The oxidation catalytic converter contains a platinum coated, ceramic, honeycombed structure. Through a chemical reaction, the platinum oxidizes HC and CO and converts them to carbon dioxide and water vapor. Effective operation of this type of catalyst requires temperatures of 600° F or higher as well as an adequate supply of oxygen in the exhaust system. Oxidation catalysts will normally ``light off'' (start oxidation) within two minutes after the first start of a cold engine. Three-Way Catalyst The three-way catalytic converter contains rhodium which reduces or separates oxides of nitrogen (NOx) into nitrogen and oxygen. This action provides better exhaust emission control than is obtainable by using only exhaust gas recirculation, an oxidation catalyst or engine modifications. Its use allows richer air-fuel mixtures, more spark advance and less exhaust gas recirculation. All three improve both driveability and fuel economy. Effective catalytic control of all three pollutants is possible when the correct balance of excess CO is reached for reduction and excess oxygen is reduced. Therefore, it is necessary to maintain precise control of the air-fuel mixture entering the engine, keeping it very close to the stoichiometric range (chemically correct for theoretical complete combustion). The downstream catalyst, along with oxygen supplied by an air pump is used to remove the remaining HC and CO left after the exhaust gases have passed through the three-way catalyst. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Manifold Fastener Torque Manifold Fastener Torque Exhaust Manifold Screws 20 ft.lb Nuts 15 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 1348 Exhaust Manifold: Service and Repair V8-318 (5.2L) & V8-360 (5.9L) 1. Remove bolts and nuts attaching exhaust pipe to manifold. 2. Remove bolts, nuts and washers attaching manifold to cylinder head. 3. Remove manifold from cylinder head. 4. Reverse procedure to install, noting the following: a. If exhaust manifold studs came out with nuts, install new studs, applying suitable sealer on coarse thread ends. If sealer is not applied to stud threads, water leaks may develop at the studs. b. Install two bolts and conical washers at inner ends of outboard arms of manifold, then two bolts without washers on center arm of manifold. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1356 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Power Module <--> [Electronic Spark Control Module] > Component Information > Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Power Module <--> [Electronic Spark Control Module] > Component Information > Locations > Page 1360 Power Module: Description and Operation The spark control computer controls the air fuel ratio of the carburetor and the ignition timing. The computer receives signals from various sensors and processes them to determine the air fuel ratio of the carburetor and ignition timing. There are as many as six types of sensors which can be used to supply the spark control computer with the necessary information needed to fire the spark plugs at the precise moment and, with the feedback carburetor, change the air-fuel ratio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1369 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1370 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1371 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1372 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1373 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1374 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1375 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1376 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1377 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1378 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1379 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1380 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1381 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1382 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1383 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock Technical Service Bulletin # 181985A Date: 851201 Fuel System - Vapor Lock Models 1981-1985 Van & Wagon Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 20, 1985 No. 18-19-85 REVISION A P-4782-C This bulletin supersedes Technical Service Bulletin #18-19-85 which should be removed from your files. The model application has been expanded to include 1981 and 1982 model years. SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING TWO PART NUMBERS: Vapor Lock Package With 22 Gallon Fuel Tank PN 4397611 Vapor Lock Package With 36 Gallon Fuel Tank PN 4397612 ADDITIONAL PARTS INFORMATION ON NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 All vehicles equipped with dual air conditioning, without electrically heated rear window defroster, and with 60 amp alternator must order the following package in addition to the vapor lock package. If vehicle is equipped with a 114 amp alternator, do not order this package or make any changes to the charging system. 1 78 AMP Alternator Package PN 4397615 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1388 Refer to parts list for contents of each package. Must be ordered separately: 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. REPAIR PROCEDURE A.Engine Compartment Harness Pn 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1A - ENGINE COMPARTMENT WIRING 3. Remove engine cover. Install the bare eyelet terminal of overlay harness, PN 4362295, to the negative terminal of the ignition coil as shown in Figure 1-A. FIGURE 1B - ENGINE COMPARTMENT WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1389 4. Route and secure the engine overlay harness, PN 4362295, along the existing main engine wiring harness using the existing wiring clips and two tie wraps, PN 6015756 (Figure 1-B). FIGURE 1C - ENGINE COMPARTMENT WIRING 5. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness to the bulkhead connector using the existing wiring clips and three tie wraps, PN 6015756 (Figure 1-C). Loop and tape any excess wire of the engine overlay harness. FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 6. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar multi-purpose grease PN 4318063, and snap into cavity #14 of the engine side of the bulkhead connector (Figure 1-D). B.Instrument Panel Harnesses Pn 4362289, All Models Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1390 FIGURE 2A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) 1. Remove instrument panel left lower trim panel. 2. Insert two bare terminals from instrument panel overlay harness, PN 4362289, into the instrument panel side of the bulkhead connector (Figure 2-A). a. Gray with black tracer wire into cavity #14. b. Dark green wire into cavity #13. INSTRUMENT PANEL WIRING 3. Secure bare eyelet ground terminal (white with black tracer wire) from instrument panel overlay harness, PN 4362289, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). NOTE: CERTAIN VEHICLES ARE ALREADY EQUIPPED WITH THE GROUND SCREW. IF SO, DISCARD THE SUPPLIED SCREW. FIGURE 2C - INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1391 FIGURE 2D - INSTRUMENT PANEL WIRING 4. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-C). Install the extracted terminal (orange wire) into the natural colored 1-way connector supplied with instrument panel overlay harness, PN 4362289. Install the bare terminal (orange wire) from the instrument panel overlay harness, PN 4362289, into the vacated cavity in the ignition switch connector. Reconnect the natural colored 1-way connectors supplied with the instrument panel overlay harness, PN 4362289, and reconnect the ignition switch connectors (Figure 2-C and 2-D). FIGURE 2E - TYPICAL CONTROL MODULE MOUNTING 5. Connect the control (auto shut-down) module, PN 5226640, to the natural colored 8-way connector from instrument panel overlay harness, PN 4362289. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1392 FIGURE 2D - INSTRUMENT PANEL WIRING FIGURE 2F - INSTRUMENT PANEL WIRING 6. Route the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289, to the back of the brake bracket for mating in a later step (Figures 2-B, 2-D, and 2-F). Secure instrument panel overlay harness, PN 4362289, using tie wrap, PN 6015756, to keep it clear of any possible interferences. Only one of the following installation procedures (Step 7) will be used. Take notice of which one applies to the vehicle being repaired. 7. Without Auxiliary Air Conditioning and/or Heater - Jumper Harness PN 4362291 a. Remove instrument panel hood and bezel assembly and remove radio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1393 FIGURE 2D - INSTRUMENT PANEL WIRING b. Route instrument panel jumper harness, PN 4362291, from the back of the brake bracket to the existing 3-way red molded connector. Secure by using existing wiring clips (Figure 2-D). c. Insert the bare bullet terminal (black with white tracer wire) from instrument panel jumper harness, PN 4362291, into the existing 3-way red molded connector from the main instrument panel wiring harness (Figure 2-D). d. Mate the orange colored 1-way connector from instrument panel jumper harness, PN 4362291, to the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). e. Reinstall instrument panel hood and bezel assembly and install radio. FIGURE 2F - INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater and Power Windows - Jumper Harness PN 4362292 a. Disconnect from each other, the two existing brown colored 1-way connectors located near the left instrument panel vent (Figure 2-F). Reconnect these two brown colored 1-way connectors to the two brown colored 1-way connectors from instrument panel jumper harness, PN 4362292 (Figure 2-F). b. Mate the orange colored 1-way connector from the instrument panel jumper harness, PN 4362292, to the orange colored 1-way connector from instrument panel overlay harness, PN 4362289 (Figure 2-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1394 INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater Without Power Windows - Relay Harness PN 4362290 a. Remove instrument panel hood and bezel assembly. Remove radio. b. Install the ignition switch protection relay, PN 4162597, to the back of the brake bracket (mounting location shown in Figure 2-B) and attach instrument panel relay harness, PN 4362290, to relay. c. Secure bare eyelet ground terminal (white wire) from instrument panel relay harness, PN 4362290, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING d. Route the dark blue wire from the instrument panel relay harness, PN 4362290 to the existing 3-way red molded connector using existing wiring clips. Insert bullet terminal (dark blue wire) into red molded connector (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1395 INSTRUMENT PANEL WIRING e. Insert bare bullet terminal (red wire) from instrument panel relay harness, PN 4362290, into the existing 3-way yellow molded connector from the main instrument panel wiring harness (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING f. Mate the orange colored 1-way connector from instrument panel relay harness, PN 4362290, to the colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). g. Install the instrument panel left lower trim panel, instrument panel hood, bezel assembly and radio. C.In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Feed red and yellow molds of body wiring harness, PN 4362293, through slot in the crossmember. Remove existing screw for gauge unit ground. Install eyelet terminal of harness, PN 4362293 (and ground eyelet terminal of 36 gallon tank gauge/pump unit) and torque ground screw to 36 inch pounds. CAUTION: GROUND SCREW MUST BE TIGHTENED SECURELY TO OPERATE ELECTRIC PUMP AND GAUGE UNIT. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1396 FIGURE 3A - BODY WIRING FIGURE 3B - BODY WIRING Install red mold of body harness, PN 4362293, onto red stud of gauge/pump unit. Install yellow mold of harness, PN 4362293, onto black stud of gauge/pump unit (figure 3-a or 3-b). Install molded blade terminal of harness, PN 4362293, onto blade terminal of 22 gallon gauge unit only. NOTE: PREVIOUS GAUGE UNIT GROUND WILL NOT BE USED ON 22 GALLON GAUGE/PUMP UNIT. ON 36 GALLON GAUGE PUMP UNIT, THE GROUND WIRE ON HARNESS PN 4362293 WILL NOT BE USED. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. Set aside the rest of harness, PN 4362293, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. D.Body Wiring Harness Pn 4362293 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1397 FIGURE 3C - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1398 FIGURE 3-F - BODY WIRING 1. Vehicles With 36 Gallon Tank Route harness, PN 4362293, to the right (passenger) side of vehicle along the fuel line tubes and tie wrap (1). At right frame rail, route harness forward to next crossmember (Figures 3-C and 3-E). Tie wrap harness in three (3) places. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1399 FIGURE 3D - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1400 FIGURE 3-F - BODY WIRING Vehicles With 22 Gallon Tank Route harness, PN 4362293, along right frame rail following brake lines (Figures 3-D and 3-E). Tie wrap in two (2) places. NOTE: HARNESS MUST BE ABOVE SHOCK STRUT WITH EITHER 36 OR 22 GALLON TANK. 2. At crossmember, route harness to the left rail following existing brake lines and tie wrap in two (2) places. At left rail, route harness forward through access holes following existing brake lines. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1401 FIGURE 3-F - BODY WIRING NOTE: HARNESS SHOULD BE TIGHT IN THIS AREA THE WRAP IN FOUR (4) PLACES (FIGURE 3-E). 3. At engine compartment, route harness through existing speedometer cable clips to bulkhead connector. If excess wiring exists; loop, tie wrap (2), and install into existing clip (Figure 3-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1402 FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 4. Plug bare terminal of harness, PN 4362293, into cavity #13 of the bulkhead connector (Figure 1-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1403 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1404 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1405 FIGURE 9 - ELECTRIC FUEL PUMP WIRING DIAGRAMW/AUX A/C & HEATER-W/O POWER WINDOWS 5. For all vehicles except those which require a 78 amp alternator package: Reinstall instrument panel side, then engine compartment side of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURES 7, 8, OR 9 FOR OVERALL WIRING DIAGRAMS. E.Engine Compartment Fuel Reservoir/Filter Lnstallation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1406 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER 1. Using template, PN 4418011, mark and drill (from engine side of passenger side chassis rail) two (2) holes .290" diameter (L size drill) as shown in Figure 4-A. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1407 FIGURE 4B - Mounting Fuel Resevoir/Filter 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. NOTE: RUBBER SPLASH SHIELD MAY HAVE TO BE CUT OUT AROUND FUEL RESERVOIR. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube, PN 4306968 (Figure 4-B). 4. Install return hose assembly, PN 4418006, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end (Figure 4-B). 5. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 42O3576. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1408 FIGURE 4B - Mounting Fuel Resevoir/Filter 6. Install one 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the fuel pump outlet tube to the reservoir/filter inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). 7. Install the other 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 8. Tighten all hose clamps to 10 inch pounds. FIGURE 10 9. Type Authorized Modification Label, PN 4275086, as shown in Figure 10 and attach near VECI label. 10. For all models except 1981-1984 equipped with Carter Thermoquad 4BBL carburetor or dual air conditioning units without electrically Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1409 heated rear window defroster. Reconnect battery. Start the engine, and inspect the entire system for fuel leaks and proper wire and hose routing. 11. Reinstall engine cover. F.1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (Pn 4397 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6O22254, (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT, AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6O22254. THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1410 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference with nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose-to-regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. For all models except those equipped with dual air conditioning units, without electrically heated rear window defroster and with 60 amp alternator: 6. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 7. Reinstall engine cover. G.Vehicles Equipped With Dual Air Conditioning Units, Without Electrically Heated Rear Defroster, and With 60 Amp Alternator. I Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1411 HEADLAMP AND DASH WIRING ASSEMBLY 1. Disconnect the battery positive lead (single in-line connection) from the headlamp and dash wiring assembly (Figure 6-A). FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 2. Remove the following wires from the engine compartment side of the bulkhead connector (Figure 6-B). a. Red wire from cavity #39 (ammeter). b. Black wire from cavity #33 (ammeter). Cut off the terminals and wrap tape around each end of both wires to insure that shorting cannot occur. Then tape the wrapped wires back against the main harness. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1412 FIGURE 6-C - 78 AMP ALTERNATOR WIRING 3. Remove the alternator output wire (heavy gauge) from the 60 amp alternator (Figure 6-C). Cut the wire off leaving approximately three (3) inches of wire extending out of the main harness. Tape the end of the lead thoroughly. Then fold and tape the lead back against the main harness to prevent shorting. 4. Remove 60 amp alternator assembly and install 78 amp alternator assembly, PN 4111204, per the service manual alternator replacement procedure. HEADLAMP AND DASH WIRING ASSEMBLY Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1413 FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 5. Beginning at the bulkhead, route and connect the wiring assembly, PN 4362343, as shown in Figure 6-A. Use the existing clip for main harness and tie wrap with three (3) tie wraps, PN 6015756. Insert the two bare terminals from alternator overlay wiring harness, PN 4362343, as shown in Figure 6-B as follows: NOTE: THE 4362343 ALTERNATOR OVERLAY HARNESS WAS MANUFACTURED WITH THE RED AND BLACK WIRES REVERSED. THEREFORE, IT WILL BE NECESSARY TO INSTALL THE BLACK WIRE (LABELED RED) INTO CAVITY #39 (RED WIRE PREVIOUSLY REMOVED), AND THE RED WIRE (LABELED BLACK) INTO CAVITY #33 (BLACK WIRE PREVIOUSLY REMOVED). FAILURE TO REVERSE THESE TWO WIRES WILL RESULT IN THE AMMETER SHOWING THE OPPOSITE CHARGE INDICATION. a. Red wire into cavity #33 (ammeter) - (labeled as black wire). b. Black wire into cavity #39 (ammeter) - (labeled as red wire). 6. Install wiring assembly, PN 4362343, alternator output terminal to new 78 amp alternator. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1414 FIGURE 6A1 7. Connect the battery positive lead and the headlamp and dash wiring assembly lead to those of the alternator overlay wiring assembly, PN 4362343, as shown in circled view of Figure 6-A. 8. Reinstall instrument panel half, then engine compartment half of bulkhead connector and torque to 40 inch pounds. 9. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 10. Reinstall engine cover. POLICY: Reimbursable within the provisions of the warranty and repair manual. TIME ALLOWANCE: Labor Operation No. 14-70-17-94 - All 2.5 Hrs. Optional Equipment: 14-70-17-60 - Carter Thermoquad Carburetor 0.5 Hrs. 14-70-17-61 - With Auxiliary A/C - Without Elec. 0.7 Hrs. Rear Window Defroster 14-70-17-62 - Without Auxiliary A/C 0.3 Hrs. 14-70-17-63 - With Auxiliary A/C - Without 0.4 Hrs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1415 Power Windows FAILURE CODE: AM - Authorized Modification Part List VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 22 GALLON FUEL TANK PACKAGE PART NO. 4397611 QTY PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075432 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Seal - Fuel Tank Gauge 3404451 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 36 GALLON FUEL TANK PACKAGE PART NO. 4397612 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075436 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Gasket - Fuel Tank Sending Unit 4115209 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1416 *It may be necessary to order clamp separately on early released packages. PARTS LIST FUEL PRESSURE REGULATOR PACKAGE FOR 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO.4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 PARTS LIST 78 AMP ALTERNATOR PACKAGE FOR 1981-1985 B MODEL TRUCKS WITH 5.2L OR 5.9L ENGINES PACKAGE PART NO. 4397615 QTY. PART NAME PART NO. 1 78 AMP Alternator Assembly - Complete 4111204 1 Alternator Overlay Wiring Harness 4362343 4 Tie Wrap 6015756 1 Gasket - Bulkhead Connector 4055399 FIGURE 4B - Mounting Fuel Resevoir/Filter 1. Fuel Filter/ Reservoir - 4418012 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1417 2. Screw - Self Tapping - 6022777 (2 Req.) 3. Tube Assy - Fuel Pump to Reservoir - 4306968 4. Return Hose & Sleeve Assy - 4418006 5. Hose Clamps - 6500650 (2 Req.) - 1/4" 6. Hose-Fuel Pump Outlet to Reservoir Inlet - 4203576 7. Hose-Reservoir Outlet to Carburetor or Regulator Fuel Tube - 4203576 8. Hose Clamps - 6500651 (4 Req.) - 5/16" Included but not shown: 2 piece Convolute Tubing - 4279993 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1 SCREW & WASHER - 6022254 2 REGULATOR BRACKET - 4418010 3 REGULATOR - 4418OD9 4 TUBE - REGULATOR TO CARB - 4418008 5 TUBE - RESERVOIR HOSE TO REGULATOR - 4418014 6 SCREW (2 EA.) - REGULATOR TO BRACKET - 6033066 7 CLAMP (5116) - 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 182985 > Jun > 85 > ECM Warm Surge At Steady Speed Powertrain Control Module: Customer Interest ECM - Warm Surge At Steady Speed Models 1985 Trucks Equipped With 5.2L-2BBL Engine, O2 Feedback Carburetor System & Automatic Transmission With California Emissions Package Subject Warm Surge at Steady Speed Index DRIVEABILITY Date June 24, 1985 No.. 18-29-85 SYMPTOM/CONDITION Vehicle will exhibit a surge at steady speeds with engine at full operating temperature. PARTS REQUIRED Driveability Package PN 4397618 Contains: 1 Vacuum Delay Valve PN 4173433 1 Hose Routing Label PN 4179843 Must be ordered separately: 1 ESA Module PN 4289977 1 CVSCC PN 4095231 1 Authorized Modification Label PN 4275086 REPAIR PROCEDURE 1. Remove existing ESA module (PN 4289637) and install supplied ESA module, PN 4289977. 2. Drain coolant and remove existing CVSCC (coolant vacuum switch cold closed) and install supplied CVSCC, PN 4095231. 3. Cut one 1-1/2" section of 3/16" vacuum hose, PN 4105167 (serviced in 50 foot rolls). 4. Install the 1-1/2" section of 3/16" hose on the natural colored end of the vacuum delay valve, PN 4173433, supplied in package. 5. The EGR solenoid is mounted on the fender shield (right side of engine compartment). It can be identified by a "white" right angle vacuum connector. Remove the white right angle vacuum connector on the EGR solenoid and install the delay valve assembly on the EGR solenoid. The 1-1/2" piece of 3/16" hose is attached in place of the removed white right angle connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 182985 > Jun > 85 > ECM Warm Surge At Steady Speed > Page 1422 FIGURE 1 - Vacuum Delay Valve - Attachment Procedure The white right angle connector is then attached to the orange colored side of the vacuum delay valve (Figure 1). 6. Wipe existing hose routing label clean. Install hose routing label, PN 4179843, supplied in package over the original label. FIGURE 2 7. Type Authorized Modification Label, PN 4275086, as shown in Figure 2 and install next to the VECI label. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 08-15-61-90 Trucks 0.5 Hrs. Vans 0.6 Hrs. FAILURE CODE: AM - Authorized Modification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1428 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1429 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1430 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1431 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1432 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1433 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1434 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1435 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1436 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1437 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1438 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1439 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1440 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1441 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1442 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock Technical Service Bulletin # 181985A Date: 851201 Fuel System - Vapor Lock Models 1981-1985 Van & Wagon Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 20, 1985 No. 18-19-85 REVISION A P-4782-C This bulletin supersedes Technical Service Bulletin #18-19-85 which should be removed from your files. The model application has been expanded to include 1981 and 1982 model years. SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING TWO PART NUMBERS: Vapor Lock Package With 22 Gallon Fuel Tank PN 4397611 Vapor Lock Package With 36 Gallon Fuel Tank PN 4397612 ADDITIONAL PARTS INFORMATION ON NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 All vehicles equipped with dual air conditioning, without electrically heated rear window defroster, and with 60 amp alternator must order the following package in addition to the vapor lock package. If vehicle is equipped with a 114 amp alternator, do not order this package or make any changes to the charging system. 1 78 AMP Alternator Package PN 4397615 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1447 Refer to parts list for contents of each package. Must be ordered separately: 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. REPAIR PROCEDURE A.Engine Compartment Harness Pn 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1A - ENGINE COMPARTMENT WIRING 3. Remove engine cover. Install the bare eyelet terminal of overlay harness, PN 4362295, to the negative terminal of the ignition coil as shown in Figure 1-A. FIGURE 1B - ENGINE COMPARTMENT WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1448 4. Route and secure the engine overlay harness, PN 4362295, along the existing main engine wiring harness using the existing wiring clips and two tie wraps, PN 6015756 (Figure 1-B). FIGURE 1C - ENGINE COMPARTMENT WIRING 5. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness to the bulkhead connector using the existing wiring clips and three tie wraps, PN 6015756 (Figure 1-C). Loop and tape any excess wire of the engine overlay harness. FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 6. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar multi-purpose grease PN 4318063, and snap into cavity #14 of the engine side of the bulkhead connector (Figure 1-D). B.Instrument Panel Harnesses Pn 4362289, All Models Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1449 FIGURE 2A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) 1. Remove instrument panel left lower trim panel. 2. Insert two bare terminals from instrument panel overlay harness, PN 4362289, into the instrument panel side of the bulkhead connector (Figure 2-A). a. Gray with black tracer wire into cavity #14. b. Dark green wire into cavity #13. INSTRUMENT PANEL WIRING 3. Secure bare eyelet ground terminal (white with black tracer wire) from instrument panel overlay harness, PN 4362289, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). NOTE: CERTAIN VEHICLES ARE ALREADY EQUIPPED WITH THE GROUND SCREW. IF SO, DISCARD THE SUPPLIED SCREW. FIGURE 2C - INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1450 FIGURE 2D - INSTRUMENT PANEL WIRING 4. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-C). Install the extracted terminal (orange wire) into the natural colored 1-way connector supplied with instrument panel overlay harness, PN 4362289. Install the bare terminal (orange wire) from the instrument panel overlay harness, PN 4362289, into the vacated cavity in the ignition switch connector. Reconnect the natural colored 1-way connectors supplied with the instrument panel overlay harness, PN 4362289, and reconnect the ignition switch connectors (Figure 2-C and 2-D). FIGURE 2E - TYPICAL CONTROL MODULE MOUNTING 5. Connect the control (auto shut-down) module, PN 5226640, to the natural colored 8-way connector from instrument panel overlay harness, PN 4362289. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1451 FIGURE 2D - INSTRUMENT PANEL WIRING FIGURE 2F - INSTRUMENT PANEL WIRING 6. Route the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289, to the back of the brake bracket for mating in a later step (Figures 2-B, 2-D, and 2-F). Secure instrument panel overlay harness, PN 4362289, using tie wrap, PN 6015756, to keep it clear of any possible interferences. Only one of the following installation procedures (Step 7) will be used. Take notice of which one applies to the vehicle being repaired. 7. Without Auxiliary Air Conditioning and/or Heater - Jumper Harness PN 4362291 a. Remove instrument panel hood and bezel assembly and remove radio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1452 FIGURE 2D - INSTRUMENT PANEL WIRING b. Route instrument panel jumper harness, PN 4362291, from the back of the brake bracket to the existing 3-way red molded connector. Secure by using existing wiring clips (Figure 2-D). c. Insert the bare bullet terminal (black with white tracer wire) from instrument panel jumper harness, PN 4362291, into the existing 3-way red molded connector from the main instrument panel wiring harness (Figure 2-D). d. Mate the orange colored 1-way connector from instrument panel jumper harness, PN 4362291, to the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). e. Reinstall instrument panel hood and bezel assembly and install radio. FIGURE 2F - INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater and Power Windows - Jumper Harness PN 4362292 a. Disconnect from each other, the two existing brown colored 1-way connectors located near the left instrument panel vent (Figure 2-F). Reconnect these two brown colored 1-way connectors to the two brown colored 1-way connectors from instrument panel jumper harness, PN 4362292 (Figure 2-F). b. Mate the orange colored 1-way connector from the instrument panel jumper harness, PN 4362292, to the orange colored 1-way connector from instrument panel overlay harness, PN 4362289 (Figure 2-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1453 INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater Without Power Windows - Relay Harness PN 4362290 a. Remove instrument panel hood and bezel assembly. Remove radio. b. Install the ignition switch protection relay, PN 4162597, to the back of the brake bracket (mounting location shown in Figure 2-B) and attach instrument panel relay harness, PN 4362290, to relay. c. Secure bare eyelet ground terminal (white wire) from instrument panel relay harness, PN 4362290, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING d. Route the dark blue wire from the instrument panel relay harness, PN 4362290 to the existing 3-way red molded connector using existing wiring clips. Insert bullet terminal (dark blue wire) into red molded connector (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1454 INSTRUMENT PANEL WIRING e. Insert bare bullet terminal (red wire) from instrument panel relay harness, PN 4362290, into the existing 3-way yellow molded connector from the main instrument panel wiring harness (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING f. Mate the orange colored 1-way connector from instrument panel relay harness, PN 4362290, to the colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). g. Install the instrument panel left lower trim panel, instrument panel hood, bezel assembly and radio. C.In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Feed red and yellow molds of body wiring harness, PN 4362293, through slot in the crossmember. Remove existing screw for gauge unit ground. Install eyelet terminal of harness, PN 4362293 (and ground eyelet terminal of 36 gallon tank gauge/pump unit) and torque ground screw to 36 inch pounds. CAUTION: GROUND SCREW MUST BE TIGHTENED SECURELY TO OPERATE ELECTRIC PUMP AND GAUGE UNIT. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1455 FIGURE 3A - BODY WIRING FIGURE 3B - BODY WIRING Install red mold of body harness, PN 4362293, onto red stud of gauge/pump unit. Install yellow mold of harness, PN 4362293, onto black stud of gauge/pump unit (figure 3-a or 3-b). Install molded blade terminal of harness, PN 4362293, onto blade terminal of 22 gallon gauge unit only. NOTE: PREVIOUS GAUGE UNIT GROUND WILL NOT BE USED ON 22 GALLON GAUGE/PUMP UNIT. ON 36 GALLON GAUGE PUMP UNIT, THE GROUND WIRE ON HARNESS PN 4362293 WILL NOT BE USED. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. Set aside the rest of harness, PN 4362293, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. D.Body Wiring Harness Pn 4362293 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1456 FIGURE 3C - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1457 FIGURE 3-F - BODY WIRING 1. Vehicles With 36 Gallon Tank Route harness, PN 4362293, to the right (passenger) side of vehicle along the fuel line tubes and tie wrap (1). At right frame rail, route harness forward to next crossmember (Figures 3-C and 3-E). Tie wrap harness in three (3) places. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1458 FIGURE 3D - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1459 FIGURE 3-F - BODY WIRING Vehicles With 22 Gallon Tank Route harness, PN 4362293, along right frame rail following brake lines (Figures 3-D and 3-E). Tie wrap in two (2) places. NOTE: HARNESS MUST BE ABOVE SHOCK STRUT WITH EITHER 36 OR 22 GALLON TANK. 2. At crossmember, route harness to the left rail following existing brake lines and tie wrap in two (2) places. At left rail, route harness forward through access holes following existing brake lines. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1460 FIGURE 3-F - BODY WIRING NOTE: HARNESS SHOULD BE TIGHT IN THIS AREA THE WRAP IN FOUR (4) PLACES (FIGURE 3-E). 3. At engine compartment, route harness through existing speedometer cable clips to bulkhead connector. If excess wiring exists; loop, tie wrap (2), and install into existing clip (Figure 3-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1461 FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 4. Plug bare terminal of harness, PN 4362293, into cavity #13 of the bulkhead connector (Figure 1-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1462 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1463 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1464 FIGURE 9 - ELECTRIC FUEL PUMP WIRING DIAGRAMW/AUX A/C & HEATER-W/O POWER WINDOWS 5. For all vehicles except those which require a 78 amp alternator package: Reinstall instrument panel side, then engine compartment side of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURES 7, 8, OR 9 FOR OVERALL WIRING DIAGRAMS. E.Engine Compartment Fuel Reservoir/Filter Lnstallation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1465 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER 1. Using template, PN 4418011, mark and drill (from engine side of passenger side chassis rail) two (2) holes .290" diameter (L size drill) as shown in Figure 4-A. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1466 FIGURE 4B - Mounting Fuel Resevoir/Filter 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. NOTE: RUBBER SPLASH SHIELD MAY HAVE TO BE CUT OUT AROUND FUEL RESERVOIR. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube, PN 4306968 (Figure 4-B). 4. Install return hose assembly, PN 4418006, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end (Figure 4-B). 5. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 42O3576. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1467 FIGURE 4B - Mounting Fuel Resevoir/Filter 6. Install one 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the fuel pump outlet tube to the reservoir/filter inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). 7. Install the other 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 8. Tighten all hose clamps to 10 inch pounds. FIGURE 10 9. Type Authorized Modification Label, PN 4275086, as shown in Figure 10 and attach near VECI label. 10. For all models except 1981-1984 equipped with Carter Thermoquad 4BBL carburetor or dual air conditioning units without electrically Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1468 heated rear window defroster. Reconnect battery. Start the engine, and inspect the entire system for fuel leaks and proper wire and hose routing. 11. Reinstall engine cover. F.1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (Pn 4397 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6O22254, (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT, AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6O22254. THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1469 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference with nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose-to-regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. For all models except those equipped with dual air conditioning units, without electrically heated rear window defroster and with 60 amp alternator: 6. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 7. Reinstall engine cover. G.Vehicles Equipped With Dual Air Conditioning Units, Without Electrically Heated Rear Defroster, and With 60 Amp Alternator. I Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1470 HEADLAMP AND DASH WIRING ASSEMBLY 1. Disconnect the battery positive lead (single in-line connection) from the headlamp and dash wiring assembly (Figure 6-A). FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 2. Remove the following wires from the engine compartment side of the bulkhead connector (Figure 6-B). a. Red wire from cavity #39 (ammeter). b. Black wire from cavity #33 (ammeter). Cut off the terminals and wrap tape around each end of both wires to insure that shorting cannot occur. Then tape the wrapped wires back against the main harness. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1471 FIGURE 6-C - 78 AMP ALTERNATOR WIRING 3. Remove the alternator output wire (heavy gauge) from the 60 amp alternator (Figure 6-C). Cut the wire off leaving approximately three (3) inches of wire extending out of the main harness. Tape the end of the lead thoroughly. Then fold and tape the lead back against the main harness to prevent shorting. 4. Remove 60 amp alternator assembly and install 78 amp alternator assembly, PN 4111204, per the service manual alternator replacement procedure. HEADLAMP AND DASH WIRING ASSEMBLY Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1472 FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 5. Beginning at the bulkhead, route and connect the wiring assembly, PN 4362343, as shown in Figure 6-A. Use the existing clip for main harness and tie wrap with three (3) tie wraps, PN 6015756. Insert the two bare terminals from alternator overlay wiring harness, PN 4362343, as shown in Figure 6-B as follows: NOTE: THE 4362343 ALTERNATOR OVERLAY HARNESS WAS MANUFACTURED WITH THE RED AND BLACK WIRES REVERSED. THEREFORE, IT WILL BE NECESSARY TO INSTALL THE BLACK WIRE (LABELED RED) INTO CAVITY #39 (RED WIRE PREVIOUSLY REMOVED), AND THE RED WIRE (LABELED BLACK) INTO CAVITY #33 (BLACK WIRE PREVIOUSLY REMOVED). FAILURE TO REVERSE THESE TWO WIRES WILL RESULT IN THE AMMETER SHOWING THE OPPOSITE CHARGE INDICATION. a. Red wire into cavity #33 (ammeter) - (labeled as black wire). b. Black wire into cavity #39 (ammeter) - (labeled as red wire). 6. Install wiring assembly, PN 4362343, alternator output terminal to new 78 amp alternator. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1473 FIGURE 6A1 7. Connect the battery positive lead and the headlamp and dash wiring assembly lead to those of the alternator overlay wiring assembly, PN 4362343, as shown in circled view of Figure 6-A. 8. Reinstall instrument panel half, then engine compartment half of bulkhead connector and torque to 40 inch pounds. 9. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 10. Reinstall engine cover. POLICY: Reimbursable within the provisions of the warranty and repair manual. TIME ALLOWANCE: Labor Operation No. 14-70-17-94 - All 2.5 Hrs. Optional Equipment: 14-70-17-60 - Carter Thermoquad Carburetor 0.5 Hrs. 14-70-17-61 - With Auxiliary A/C - Without Elec. 0.7 Hrs. Rear Window Defroster 14-70-17-62 - Without Auxiliary A/C 0.3 Hrs. 14-70-17-63 - With Auxiliary A/C - Without 0.4 Hrs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1474 Power Windows FAILURE CODE: AM - Authorized Modification Part List VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 22 GALLON FUEL TANK PACKAGE PART NO. 4397611 QTY PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075432 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Seal - Fuel Tank Gauge 3404451 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 36 GALLON FUEL TANK PACKAGE PART NO. 4397612 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075436 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Gasket - Fuel Tank Sending Unit 4115209 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1475 *It may be necessary to order clamp separately on early released packages. PARTS LIST FUEL PRESSURE REGULATOR PACKAGE FOR 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO.4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 PARTS LIST 78 AMP ALTERNATOR PACKAGE FOR 1981-1985 B MODEL TRUCKS WITH 5.2L OR 5.9L ENGINES PACKAGE PART NO. 4397615 QTY. PART NAME PART NO. 1 78 AMP Alternator Assembly - Complete 4111204 1 Alternator Overlay Wiring Harness 4362343 4 Tie Wrap 6015756 1 Gasket - Bulkhead Connector 4055399 FIGURE 4B - Mounting Fuel Resevoir/Filter 1. Fuel Filter/ Reservoir - 4418012 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1476 2. Screw - Self Tapping - 6022777 (2 Req.) 3. Tube Assy - Fuel Pump to Reservoir - 4306968 4. Return Hose & Sleeve Assy - 4418006 5. Hose Clamps - 6500650 (2 Req.) - 1/4" 6. Hose-Fuel Pump Outlet to Reservoir Inlet - 4203576 7. Hose-Reservoir Outlet to Carburetor or Regulator Fuel Tube - 4203576 8. Hose Clamps - 6500651 (4 Req.) - 5/16" Included but not shown: 2 piece Convolute Tubing - 4279993 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1 SCREW & WASHER - 6022254 2 REGULATOR BRACKET - 4418010 3 REGULATOR - 4418OD9 4 TUBE - REGULATOR TO CARB - 4418008 5 TUBE - RESERVOIR HOSE TO REGULATOR - 4418014 6 SCREW (2 EA.) - REGULATOR TO BRACKET - 6033066 7 CLAMP (5116) - 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 182985 > Jun > 85 > ECM - Warm Surge At Steady Speed Powertrain Control Module: All Technical Service Bulletins ECM - Warm Surge At Steady Speed Models 1985 Trucks Equipped With 5.2L-2BBL Engine, O2 Feedback Carburetor System & Automatic Transmission With California Emissions Package Subject Warm Surge at Steady Speed Index DRIVEABILITY Date June 24, 1985 No.. 18-29-85 SYMPTOM/CONDITION Vehicle will exhibit a surge at steady speeds with engine at full operating temperature. PARTS REQUIRED Driveability Package PN 4397618 Contains: 1 Vacuum Delay Valve PN 4173433 1 Hose Routing Label PN 4179843 Must be ordered separately: 1 ESA Module PN 4289977 1 CVSCC PN 4095231 1 Authorized Modification Label PN 4275086 REPAIR PROCEDURE 1. Remove existing ESA module (PN 4289637) and install supplied ESA module, PN 4289977. 2. Drain coolant and remove existing CVSCC (coolant vacuum switch cold closed) and install supplied CVSCC, PN 4095231. 3. Cut one 1-1/2" section of 3/16" vacuum hose, PN 4105167 (serviced in 50 foot rolls). 4. Install the 1-1/2" section of 3/16" hose on the natural colored end of the vacuum delay valve, PN 4173433, supplied in package. 5. The EGR solenoid is mounted on the fender shield (right side of engine compartment). It can be identified by a "white" right angle vacuum connector. Remove the white right angle vacuum connector on the EGR solenoid and install the delay valve assembly on the EGR solenoid. The 1-1/2" piece of 3/16" hose is attached in place of the removed white right angle connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 182985 > Jun > 85 > ECM - Warm Surge At Steady Speed > Page 1481 FIGURE 1 - Vacuum Delay Valve - Attachment Procedure The white right angle connector is then attached to the orange colored side of the vacuum delay valve (Figure 1). 6. Wipe existing hose routing label clean. Install hose routing label, PN 4179843, supplied in package over the original label. FIGURE 2 7. Type Authorized Modification Label, PN 4275086, as shown in Figure 2 and install next to the VECI label. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 08-15-61-90 Trucks 0.5 Hrs. Vans 0.6 Hrs. FAILURE CODE: AM - Authorized Modification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations Powertrain Control Module: Component Locations Electronic Ignition System Components On Firewall Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 1484 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1487 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > Emissions Maintenance Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Emissions Maintenance Lamp Relay: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Emission Control Systems > Emissions Maintenance Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 1493 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Power Module <--> [Electronic Spark Control Module] > Component Information > Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Power Module <--> [Electronic Spark Control Module] > Component Information > Locations > Page 1498 Power Module: Description and Operation The spark control computer controls the air fuel ratio of the carburetor and the ignition timing. The computer receives signals from various sensors and processes them to determine the air fuel ratio of the carburetor and ignition timing. There are as many as six types of sensors which can be used to supply the spark control computer with the necessary information needed to fire the spark plugs at the precise moment and, with the feedback carburetor, change the air-fuel ratio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Specifications > Electrical Specifications Ignition Control Module: Electrical Specifications Part No. Spark Advance Test Electronic EGR Time Delay Electronic Throttle Control 4289601 38 +/- 4 deg at 2000 rpm 60 min 90 sec Note: After start or 2 sec. after throttle close condition. 4289603 33 +/- 4 deg at 2000 rpm 45 min 60 sec Note: After start or 1 sec. after throttle close condition. 4289613 30 +/- 4 deg at 2000 rpm 60 min 90 sec Note: After start or 1 sec. after throttle close condition. 4289615 30 +/- 4 deg at 2000 rpm 28 min 60 sec Note: After start or 2 sec. after throttle close condition. 4289617 30 +/- 4 deg at 2000 rpm 65 min 60 sec 4289621 37 +/- 4 deg at 2000 rpm 60 min --4289637 34 +/- 4 deg at 2000 rpm 25 min 25 sec Note: After start or 1 sec. after throttle close position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Specifications > Electrical Specifications > Page 1503 Ignition Control Module: Mechanical Specifications Part No. Spark Advance Test Electronic EGR Time Delay Electronic Throttle Control 4289601 38 +/- 4 deg at 2000 rpm 60 min 90 sec Note: After start or 2 sec. after throttle close condition. 4289603 33 +/- 4 deg at 2000 rpm 45 min 60 sec Note: After start or 1 sec. after throttle close condition. 4289613 30 +/- 4 deg at 2000 rpm 60 min 90 sec Note: After start or 1 sec. after throttle close condition. 4289615 30 +/- 4 deg at 2000 rpm 28 min 60 sec Note: After start or 2 sec. after throttle close condition. 4289617 30 +/- 4 deg at 2000 rpm 65 min 60 sec 4289621 37 +/- 4 deg at 2000 rpm 60 min --4289637 34 +/- 4 deg at 2000 rpm 25 min 25 sec Note: After start or 1 sec. after throttle close position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1506 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Spark Control Relay > Component Information > Locations Spark Control Relay: Locations Electronic Ignition System Components On Firewall Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1516 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 1521 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations Coolant Temperature Sensor/Switch (For Computer): Component Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 1524 Coolant Temperature Sensor/Switch (For Computer): Connector Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 1525 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Coolant Temperature Switch Coolant Temperature Sensor/Switch (For Computer): Description and Operation Coolant Temperature Switch Fig. 4 Switches & sensors location. V8 engine On V8 engines the coolant switch is located on the front of the intake manifold, Fig. 4. It operates by supplying a signal to the computer when the engine coolant temperature is below 150~ F. This information is required to prevent a change in air fuel ratio until engine operation temperature is reached except there is no control of canister purging. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Coolant Temperature Switch > Page 1528 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Description The coolant temperature sensor measures temperature of the engine coolant. The coolant temperature sensor is mounted in the thermostat housing or in water passage of intake manifold. The sensor monitors engine coolant (operating) temperature. It supplies the logic module with a voltage signal which varies with coolant temperature. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1533 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control Crankshaft Position Sensor: Service and Repair RWD W/ Electronic Spark Control Removal & Installation Removal 1. Disconnect vacuum line at distributor, if equipped. 2. Disconnect distributor pickup lead(s) at wiring harness connector, then remove distributor cap. 3. Mark position of rotor on distributor body and engine block surface so that distributor can be installed in the same position. 4. Remove hold-down and/or bolt and lift distributor from engine. Installation 1. If engine was cranked after distributor was removed from engine, rotate crankshaft to bring No. 1 piston up on its compression stroke and align timing mark on crankshaft pulley with ``O'' (TDC) mark on timing cover. 2. With distributor gasket or O-ring in place, hold distributor over mounting pad. 3. Turn rotor to a position just ahead of the No. 1 distributor cap terminal. 4. Install distributor, engaging distributor gear with camshaft drive gear on 6 cylinder engines. On V-8 engines, engage tang of distributor shaft with slot in oil pump drive gear. With distributor fully seated on engine, rotor should be under No. 1 cap terminal. 5. Install distributor hold-down and/or bolt, distributor cap, pickup lead(s) and vacuum line. 6. Adjust ignition timing to specifications found in the Tune Up section. Distributor Shaft & Bushing Wear Test 1. Remove distributor from vehicle and clamp distributor in a vise. Use extreme caution not to damage distributor. 2. Attach a dial indicator to housing so plunger rests against reluctor sleeve. 3. Place a wire loop around reluctor sleeve and hook a spring scale on the other end of the loop. Apply a 1-1/2 lb. pull toward dial indicator. Apply a 1 lb. pull away from dial indicator and read movement on indicator. 4. Movement must not exceed .006 inch. If movement exceeds limit, replace either housing or shaft to bring movement back within tolerance. Distributor Disassembly 1. Remove rotor and vacuum advance unit, if equipped Fig. 14. 2. Remove reluctor by prying up from bottom of reluctor using two screwdrivers with a maximum blade width of 7/16 in. Use care not to damage or distort reluctor teeth. 3. Remove two screws and lockwashers attaching lower plate to distributor housing, then lift out lower plate, upper plate and pickup coil as an assembly. Do not remove distributor cap clamp springs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 1536 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 4. On eight cylinder units, if distributor housing, shaft, reluctor sleeve or governor weights are to be replace, proceed as follows: a. Remove distributor shaft retaining pin and slide retainer off end of shaft. b. If necessary, use a file to clean burrs from around pin hole area on shaft, then remove lower thrust washer. c. Push shaft upward and remove from distributor housing. Distributor Assembly Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 1537 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 1. Lubricate and test operation of governor weights. Inspect weight springs for distortion and bearing surfaces and pins for damage. 2. Lubricate upper thrust washer and install onto shaft. Install shaft into housing. 3. On eight cylinder units, install distributor shaft retainer and pin, Fig. 14. 4. On all units, install lower plate, upper plate and pickup coil assembly. 5. Attach vacuum advance unit to pickup plate, then install vacuum advance unit attaching screws and washers. 6. Position reluctor keeper pin into place on reluctor sleeve, then slide reluctor down reluctor sleeve and press firmly into position. Install keeper pin. 7. Lubricate felt pad located in top of reluctor sleeve with one drop of light engine oil, then install rotor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 1538 Crankshaft Position Sensor: Service and Repair RWD W/O Electronic Spark Control Removal & Installation Removal 1. Disconnect vacuum line at distributor, if equipped. 2. Disconnect distributor pickup lead(s) at wiring harness connector, then remove distributor cap. 3. Mark position of rotor on distributor body and engine block surface so that distributor can be installed in the same position. 4. Remove hold-down and/or bolt and lift distributor from engine. Installation 1. If engine was cranked after distributor was removed from engine, rotate crankshaft to bring No. 1 piston up on its compression stroke and align timing mark on crankshaft pulley with ``O'' (TDC) mark on timing cover. 2. With distributor gasket or O-ring in place, hold distributor over mounting pad. 3. Turn rotor to a position just ahead of the No. 1 distributor cap terminal. 4. Install distributor, engaging distributor gear with camshaft drive gear on 6 cylinder engines. On V-8 engines, engage tang of distributor shaft with slot in oil pump drive gear. With distributor fully seated on engine, rotor should be under No. 1 cap terminal. 5. Install distributor hold-down and/or bolt, distributor cap, pickup lead(s) and vacuum line. 6. Adjust ignition timing to specifications found in the Tune Up section. Distributor Shaft & Bushing Wear Test 1. Remove distributor from vehicle and clamp distributor in a vise. Use extreme caution not to damage distributor. 2. Attach a dial indicator to housing so plunger rests against reluctor sleeve. 3. Place a wire loop around reluctor sleeve and hook a spring scale on the other end of the loop. Apply a 1-1/2 lb. pull toward dial indicator. Apply a 1 lb. pull away from dial indicator and read movement on indicator. 4. Movement must not exceed .006 inch. If movement exceeds limit, replace either housing or shaft to bring movement back within tolerance. Distributor Disassembly 1. Remove rotor and vacuum advance unit, if equipped Fig. 14. 2. Remove reluctor by prying up from bottom of reluctor using two screwdrivers with a maximum blade width of 7/16 in. Use care not to damage or distort reluctor teeth. 3. Remove two screws and lockwashers attaching lower plate to distributor housing, then lift out lower plate, upper plate and pickup coil as an assembly. Do not remove distributor cap clamp springs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 1539 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 4. On eight cylinder units, if distributor housing, shaft, reluctor sleeve or governor weights are to be replace, proceed as follows: a. Remove distributor shaft retaining pin and slide retainer off end of shaft. b. If necessary, use a file to clean burrs from around pin hole area on shaft, then remove lower thrust washer. c. Push shaft upward and remove from distributor housing. Distributor Assembly Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 1540 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 1. Lubricate and test operation of governor weights. Inspect weight springs for distortion and bearing surfaces and pins for damage. 2. Lubricate upper thrust washer and install onto shaft. Install shaft into housing. 3. On eight cylinder units, install distributor shaft retainer and pin, Fig. 14. 4. On all units, install lower plate, upper plate and pickup coil assembly. 5. Attach vacuum advance unit to pickup plate, then install vacuum advance unit attaching screws and washers. 6. Position reluctor keeper pin into place on reluctor sleeve, then slide reluctor down reluctor sleeve and press firmly into position. Install keeper pin. 7. Lubricate felt pad located in top of reluctor sleeve with one drop of light engine oil, then install rotor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Charge Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Charge Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 1544 Charge Temperature Switch Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Charge Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 1545 Charge Temperature Sensor: Description and Operation Fig. 4 Switches & sensors location. V8 engine The CTS, Fig. 4, is used on eight cylinder engines and is located in the intake manifold No. 8 runner on eight cylinder engines. When the incoming air fuel mixture is below 60° F., the CTS will close, allowing no EGR timer function, no EGR valve operation and the air injection directed upstream into the exhaust manifold. When incoming air-fuel mixture is above 60° F., the CTS will open allowing EGR timer to expire, the EGR valve to operate and air injection switched downstream into the exhaust system. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Charge Temperature Switch <--> [Intake Air Temperature Switch] > Component Information > Locations Charge Temperature Switch: Locations Engine Mounted Switches & Sensors. Upper RH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Component Locations Detonation (Knock) Sensor: Component Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Component Locations > Page 1553 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Page 1554 Detonation (Knock) Sensor: Description and Operation Fig. 12 Detonation sensor location. V8 engine The detonation sensor, Fig. 12, is used on V8 engines only and is located in the intake manifold. It signals the computer when detonation occurs so that the ignition timing can be retarded. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications All models with TBI. Apply 5" (125mm) Hg to unit and record output voltage. Apply 20" (500mm) Hg to unit, the difference in voltage should be 2.3 - 2.9. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1558 Manifold Pressure/Vacuum Sensor: Locations Combustion Control Computer Location. Upper RH Side Of Engine Applicable to: 1981-84 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1559 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 7 Spark control computer & vacuum transducer location. V8 engine The vacuum transducer is located on the computer and it provides the computer with information on engine vacuum, Fig. 7. It is used to control spark advance and air fuel ratios. And indicates engine load. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Engine Mounted Switches & Sensors. Lower RH Side Of Engine Applicable to: V8 Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1565 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1566 Oxygen Sensor: Description and Operation Fig. 7 Spark control computer & vacuum transducer location. V8 engine To provide the EFC system with an indication of the exhaust gas composition, an oxygen sensor is threaded into the exhaust manifold and is exposed directly to exhaust gas stream, Fig. 7. The sensor is sensitive to the presence of or lack of oxygen. With an oxygen deficiency in the exhaust gas, outside oxygen diffuses through the sensor, acting as an electrolyte and generating a voltage. The oxygen sensor is basically a galvanic battery consisting of a cylindrical electrolyte element of zirconium dioxide which is coated inside and out with platinum. The outer platinum electrode is exposed to atmosphere, while the inner is exposed to the hot exhaust gases. A porous ceramic (spinel) coating protects the platinum against damage. When heated to operating temperature by the hot exhaust gases, the sensor generates a voltage. If the oxygen is high, a low voltage (below .45 volts) will be produced. When the oxygen content is low (rich mixture), a high voltage (.45 to 1 volt) will be produced. This relationship between available oxygen and sensor output voltage causes the sensor to function as a rich-lean switch. The sensor output voltage is used by the Feedback Carburetor Controller to calculate and adjust the air-fuel mixture as needed for optimum catalytic converter operation. The sensor's internal impedance, output voltage and time response are all functions of temperature. This temperature dependency is important during cold starts and other low temperature operating modes. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Throttle Body Temperature Sensor] > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Carburetor Switch <--> [Throttle Full Close Switch] > Component Information > Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Carburetor Switch <--> [Throttle Full Close Switch] > Component Information > Locations > Page 1573 Carburetor Switch: Description and Operation Fig. 4 Switches & sensors location. V8 engine The carburetor switch, Fig. 4, is located on the end of the idle stop and it signals the computer when the engine is at idle. Whenever the curb idle screw touches the carburetor switch, there will be no additional advance from the vacuum transducer or changing of the carburetor air fuel ratio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1578 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vacuum Switch > Component Information > Description and Operation Vacuum Switch: Description and Operation Fig. 7 Spark control computer & vacuum transducer location. V8 engine The vacuum transducer is located on the computer and it provides the computer with information on engine vacuum, Fig. 7. It is used to control spark advance and air fuel ratios. And indicates engine load. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Distance Sensor <--> [Vehicle Speed Sensor] > Component Information > Diagrams > Diagram Information and Instructions Distance Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Distance Sensor <--> [Vehicle Speed Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1586 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Choke Temperature Control Switch > Component Information > Locations Choke Temperature Control Switch: Locations Upper RH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Intake Air Temperature (IAT) Sensor <--> [Throttle Body Temperature Sensor] > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Carburetor Switch <--> [Throttle Full Close Switch] > Component Information > Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Carburetor Switch <--> [Throttle Full Close Switch] > Component Information > Locations > Page 1597 Carburetor Switch: Description and Operation Fig. 4 Switches & sensors location. V8 engine The carburetor switch, Fig. 4, is located on the end of the idle stop and it signals the computer when the engine is at idle. Whenever the curb idle screw touches the carburetor switch, there will be no additional advance from the vacuum transducer or changing of the carburetor air fuel ratio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1602 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1608 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1613 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control Crankshaft Position Sensor: Service and Repair RWD W/ Electronic Spark Control Removal & Installation Removal 1. Disconnect vacuum line at distributor, if equipped. 2. Disconnect distributor pickup lead(s) at wiring harness connector, then remove distributor cap. 3. Mark position of rotor on distributor body and engine block surface so that distributor can be installed in the same position. 4. Remove hold-down and/or bolt and lift distributor from engine. Installation 1. If engine was cranked after distributor was removed from engine, rotate crankshaft to bring No. 1 piston up on its compression stroke and align timing mark on crankshaft pulley with ``O'' (TDC) mark on timing cover. 2. With distributor gasket or O-ring in place, hold distributor over mounting pad. 3. Turn rotor to a position just ahead of the No. 1 distributor cap terminal. 4. Install distributor, engaging distributor gear with camshaft drive gear on 6 cylinder engines. On V-8 engines, engage tang of distributor shaft with slot in oil pump drive gear. With distributor fully seated on engine, rotor should be under No. 1 cap terminal. 5. Install distributor hold-down and/or bolt, distributor cap, pickup lead(s) and vacuum line. 6. Adjust ignition timing to specifications found in the Tune Up section. Distributor Shaft & Bushing Wear Test 1. Remove distributor from vehicle and clamp distributor in a vise. Use extreme caution not to damage distributor. 2. Attach a dial indicator to housing so plunger rests against reluctor sleeve. 3. Place a wire loop around reluctor sleeve and hook a spring scale on the other end of the loop. Apply a 1-1/2 lb. pull toward dial indicator. Apply a 1 lb. pull away from dial indicator and read movement on indicator. 4. Movement must not exceed .006 inch. If movement exceeds limit, replace either housing or shaft to bring movement back within tolerance. Distributor Disassembly 1. Remove rotor and vacuum advance unit, if equipped Fig. 14. 2. Remove reluctor by prying up from bottom of reluctor using two screwdrivers with a maximum blade width of 7/16 in. Use care not to damage or distort reluctor teeth. 3. Remove two screws and lockwashers attaching lower plate to distributor housing, then lift out lower plate, upper plate and pickup coil as an assembly. Do not remove distributor cap clamp springs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 1616 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 4. On eight cylinder units, if distributor housing, shaft, reluctor sleeve or governor weights are to be replace, proceed as follows: a. Remove distributor shaft retaining pin and slide retainer off end of shaft. b. If necessary, use a file to clean burrs from around pin hole area on shaft, then remove lower thrust washer. c. Push shaft upward and remove from distributor housing. Distributor Assembly Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 1617 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 1. Lubricate and test operation of governor weights. Inspect weight springs for distortion and bearing surfaces and pins for damage. 2. Lubricate upper thrust washer and install onto shaft. Install shaft into housing. 3. On eight cylinder units, install distributor shaft retainer and pin, Fig. 14. 4. On all units, install lower plate, upper plate and pickup coil assembly. 5. Attach vacuum advance unit to pickup plate, then install vacuum advance unit attaching screws and washers. 6. Position reluctor keeper pin into place on reluctor sleeve, then slide reluctor down reluctor sleeve and press firmly into position. Install keeper pin. 7. Lubricate felt pad located in top of reluctor sleeve with one drop of light engine oil, then install rotor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 1618 Crankshaft Position Sensor: Service and Repair RWD W/O Electronic Spark Control Removal & Installation Removal 1. Disconnect vacuum line at distributor, if equipped. 2. Disconnect distributor pickup lead(s) at wiring harness connector, then remove distributor cap. 3. Mark position of rotor on distributor body and engine block surface so that distributor can be installed in the same position. 4. Remove hold-down and/or bolt and lift distributor from engine. Installation 1. If engine was cranked after distributor was removed from engine, rotate crankshaft to bring No. 1 piston up on its compression stroke and align timing mark on crankshaft pulley with ``O'' (TDC) mark on timing cover. 2. With distributor gasket or O-ring in place, hold distributor over mounting pad. 3. Turn rotor to a position just ahead of the No. 1 distributor cap terminal. 4. Install distributor, engaging distributor gear with camshaft drive gear on 6 cylinder engines. On V-8 engines, engage tang of distributor shaft with slot in oil pump drive gear. With distributor fully seated on engine, rotor should be under No. 1 cap terminal. 5. Install distributor hold-down and/or bolt, distributor cap, pickup lead(s) and vacuum line. 6. Adjust ignition timing to specifications found in the Tune Up section. Distributor Shaft & Bushing Wear Test 1. Remove distributor from vehicle and clamp distributor in a vise. Use extreme caution not to damage distributor. 2. Attach a dial indicator to housing so plunger rests against reluctor sleeve. 3. Place a wire loop around reluctor sleeve and hook a spring scale on the other end of the loop. Apply a 1-1/2 lb. pull toward dial indicator. Apply a 1 lb. pull away from dial indicator and read movement on indicator. 4. Movement must not exceed .006 inch. If movement exceeds limit, replace either housing or shaft to bring movement back within tolerance. Distributor Disassembly 1. Remove rotor and vacuum advance unit, if equipped Fig. 14. 2. Remove reluctor by prying up from bottom of reluctor using two screwdrivers with a maximum blade width of 7/16 in. Use care not to damage or distort reluctor teeth. 3. Remove two screws and lockwashers attaching lower plate to distributor housing, then lift out lower plate, upper plate and pickup coil as an assembly. Do not remove distributor cap clamp springs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 1619 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 4. On eight cylinder units, if distributor housing, shaft, reluctor sleeve or governor weights are to be replace, proceed as follows: a. Remove distributor shaft retaining pin and slide retainer off end of shaft. b. If necessary, use a file to clean burrs from around pin hole area on shaft, then remove lower thrust washer. c. Push shaft upward and remove from distributor housing. Distributor Assembly Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 1620 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 1. Lubricate and test operation of governor weights. Inspect weight springs for distortion and bearing surfaces and pins for damage. 2. Lubricate upper thrust washer and install onto shaft. Install shaft into housing. 3. On eight cylinder units, install distributor shaft retainer and pin, Fig. 14. 4. On all units, install lower plate, upper plate and pickup coil assembly. 5. Attach vacuum advance unit to pickup plate, then install vacuum advance unit attaching screws and washers. 6. Position reluctor keeper pin into place on reluctor sleeve, then slide reluctor down reluctor sleeve and press firmly into position. Install keeper pin. 7. Lubricate felt pad located in top of reluctor sleeve with one drop of light engine oil, then install rotor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1625 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1626 Ignition Switch: Electrical Diagrams Fig. 19 Ignition Switch Less Tilt Wheel & Starter Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1627 Fig. 19 Ignition Switch Less Tilt Wheel & Starter Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1628 Fig. 20 Ignition Switch With Tilt Wheel Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 1629 Ignition Switch: Service and Repair Fig. 1 Lock cylinder removal. Less tilt steering wheel MODELS LESS TILT STEERING 1. Disconnect battery ground cable and remove turn signal switch as outlined in this chapter. 2. Remove ignition key lamp assembly attaching screws, then the assembly. 3. Remove snap ring from upper end of steering shaft. 4. Remove bearing housing to lock housing attaching screws, then the bearing housing from the shaft. 5. Remove buzzer switch attaching screws, then the buzzer switch, if equipped. 6. Remove lock lever guide plate attaching screws, then the lock plate. 7. Place lock cylinder in the "Lock" position and remove key. Using a suitable tool, depress spring loaded lock retainer and pull lock cylinder from housing bore. 8. Remove ignition switch attaching screws, then the ignition switch. 9. Reverse procedure to install. Fig. 2 Lock cylinder removal. W/tilt steering wheel MODELS WITH TILT STEERING Fig. 2 Lock cylinder removal. W/tilt steering wheel Ignition Lock, Replace Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 1630 The ignition switch and lock assembly are separate units and must be replaced individually. 1. Disconnect battery ground cable and remove turn signal switch as outlined in this chapter. 2. Place lock cylinder in the "Lock" position and remove key. Insert suitable tool into slot next to switch mounting screw boss. 3. Depress spring latch at bottom of slot, then remove lock. 4. To install ignition lock, place lock cylinder in the "Lock" position and remove key. Install lock cylinder assembly into housing, then press inward and move switch actuator rod up and down to align parts. When parts align, the lock cylinder will move inward and a spring loaded retainer will snap into place, locking cylinder into housing. Ignition Switch, Replace The ignition switch is located on the top of the steering column under the instrument panel. To replace it, the steering column should be lowered as follows: 1. Disconnect shift indicator link. 2. Remove nuts securing bracket to dash panel and carefully lower column. 3. Disconnect electrical connector from switch. Ensure switch is in "Accessory" position. 4. Remove switch attaching screws, then the switch. 5. To install ignition switch, place switch slider and lock in the "Accessory" position. 6. Fit actuator rod into switch and assemble to column. 7. Complete assembly in reverse of removal procedure. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Component Locations Detonation (Knock) Sensor: Component Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Component Locations > Page 1635 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Page 1636 Detonation (Knock) Sensor: Description and Operation Fig. 12 Detonation sensor location. V8 engine The detonation sensor, Fig. 12, is used on V8 engines only and is located in the intake manifold. It signals the computer when detonation occurs so that the ignition timing can be retarded. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pump Pressure ............................................................................................................................ ........................................................ 4.75 psi - 6.25 psi Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package Technical Service Bulletin # 250485 Date: 850506 High Altitude Conversion Package Models 1985 Light Duty Domestic Trucks Subject High Altitude Conversion Packages & Adjustment for Improved Engine Performance Index EMISSIONS Date May 6, 1985 No.. 25-04-85 P-1522-C Packages are now available to accommodate a customer who wishes to convert his 1985 low altitude vehicle for improved high altitude (over 4,000 feet above sea level) engine performance. Vehicles with the low altitude package transferred to service in high altitude areas may exhibit undesirable driveability. However, the installation of a high altitude conversion package is voluntary and at the customer's expense. The high altitude field conversion packages and procedures outlined below have been authorized on the following 1985 non-altitude equipped engine families in service at altitudes above 4,000 feet above sea level. CONVERSION INSTRUCTIONS Sea Level to Altitude FIGURE 1 - Vehicle Emission Control Information Label IMPORTANT: IN SOME OF THE CONVERSION PROCEDURES YOU WILL BE REQUIRED TO INSTALL A NEW VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL PN 4275084. THIS LABEL HAS TWO AREAS THAT ARE IMPACT IMPRINTABLE WITH A TYPEWRITER (SEE FIGURE 1). If you are required to readjust timing, curb idle speed, or fast idle speed to a specification different than the original VECI label specification, then just type in the new specification after the subject operation. If you are asked to refer to the original VECI label specifications, type in on the right hand side of the label "Refer to Original VECI Label." Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1645 In every case where this label is used, type in after - AUTHORITY OF Technical Service Bulletin #25-04-85, and your dealer code below. Label PN 4275084 is available from Parts Supply. FIGURE 2 - Vehicle Emission Control Information Label The engine family chart below will help identify the appropriate parts to be installed by recording body style and engine family from the original VECI label. This chart cross references the EPA engine family with the engine application used in the accompanying instructions (refer to Figure 2). EPA Engine Family Engine Application (Found on VECI Label) 2.2L-2V Federal FCR2.2T2AAB6 2.2L-2V 50 States FCR2.2T2HBM9 2.6L-2V Federal FCR2.6T2AAB8 3.7L-1V Federal FCR3.7T1BBA0 5.2L-2V 50 States FCR5.2T2HBN1 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1646 5.2L-2V Federal FCR5.2T2BBF6 5.9L-4V Federal FCR5.9T4BBF1 POLICY: Information only 1985 2.2L-2V Light Duty Trucks All Models With Federal Emissions Package (49 States) Dodge Ram Van, Dodge Caravan, Plymouth Voy Consisting of: 1 - #211 Primary Main Jet PN 4293797 1 - #215 Secondary Main Jet PN 4240006 1 - #180 Primary High Speed Bleed PN 4342920 1 - #210 Secondary High Speed Bleed PN 4342921 1 - Carburetor Air Horn Gasket PN 4293846 INSTRUCTIONS FIGURE 1. Holley 5220 Primary Main Metering Jet #211 FIGURE 2. Holley 5220 Secondary Main Metering Jet #223 - Remove carburetor air horn. - Remove primary and secondary main metering jets. Refer to Figures 1 and 2. - Install #211 primary main metering jet PN 4293797. - Install #215 secondary main metering jet PN 4240006. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1647 FIGURE 3. Holley 5220 Primary High Speed Bleed #180 FIGURE 4. Holley 5220 Secondary High Speed Bleed #210 - Remove primary and secondary high speed bleeds. Refer to Figures 3 and 4. - Install #180 primary high speed bleed PN 4342920. - Install #210 secondary high speed bleed PN 4342921. FIGURE 5. Holley 5220 Power Valve Location - Turn power valve (Figure 5) two full turns counterclockwise (lean). - Reinstall air horn with new air horn gasket PN 4293846. Start engine and check for leaks. - Warm up engine and set idle speed to that specified on the VECI label. - Type in changes made on Emission Update Label PN 4275084 and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1648 1985 2.2L-2V Light Duty Truck Dodge Ram Van, Dodge Caravan & Plymouth Voyager Only Equipped With "50 States" Emission Package Consisting of: 1 - Carburetor (manual or automatic PN 4342891 transmission) Also order conversion hardware package. 1 - Hardware Package PN 4342950 Consisting of: 1 - Carburetor Base Gasket PN 4095975 1 - H.A.C. PN 4306202 1 - Hose Routing Diagram NPN 1 - Mounting Bracket (H.A.C.) PN 4105199 1 - H.A.C. Hose Harness NPN 3 - Mounting Screws NPN INSTRUCTIONS - Remove carburetor per instructions in appropriate engine performance/electrical shop manual. - Install new carburetor with new base gasket. FIGURE 6 - High Altitude Compensator Mounting - Install altitude compensator with bracket (Figure 6). - Install altitude compensator vacuum hose harness, route as shown in hose routing diagram (Figure 6). - Warm up engine. - Set engine idle speed to specified VECI label specification. - Set high fast idle on Step 3 (lowest) to specification. - Double check hose routing and installation of fuel lines. - Type in changes made on the Emission Update Label PN 4275084 and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1649 1985 2.6L-2V Light Duty Truck All Models With Federal Emissions Package (49 States) Consisting of: 1 - Carburetor Jet Kit PN MD088294 containing: #110 Primary Main Jet #175 Secondary Main Jet #100 Primary Air Bleed Jet #120 Secondary Air Bleed Jet 1 - Float Chamber Cover Gasket PN MD608639 1 - Choke Cover Screw Kit PN MD606977 1 - Carburetor Flange Gasket PN MD025344 INSTRUCTIONS - Remove carburetor from engine and take off air horn per instructions in appropriate service manual. FIGURE 7 - Mikuni Jet Locations - Remove primary and secondary main jets as shown in Figure 7. - Install #110 primary main jet and #175 secondary main jet in the primary and secondary pedestals. - Reinstall air horn on carburetor using new air horn gasket PN MD608639 and choke cover screw kit PN MD606977. FIGURE 8 - Mikuni Air Bleed Jet Locations - Remove primary and secondary air bleed jets shown in Figure 8. - Prepare carburetor for propane idle set by drilling out concealment plug. - Install #120 secondary air bleed jet and #100 primary air bleed jet. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1650 - Reinstall carburetor on engine using a new carburetor flange gasket, PN MD025344. - Remove vacuum controlled orificed tank vapor valve (VCOTV) and the vacuum/line(s) to the valve. - Remove the 3/16" tank vent line from the vapor canister and replace with 24" of 3/16" tank vent line and route directly to steel tank vent tube. - Remove the manifold vacuum line from the manifold vacuum tee (originally to the VCOTV) and cap the tee. - Remove the EGR delay valve at the corresponding EGR and carburetor ports and replace with 8" of bulk 3/16" vacuum line from stock. - Start engine and warm up to operating temperature. - Set idle rpm (curb) to 850 rpm and propane enriched rpm to 950 rpm. - Set throttle kicker rpm to 1050 rpm. FIGURE 9 - Authorized Modifications Label - Type in changes made on Authorized Modification Label, PN 4275086 (Figure 9), and affix to engine compartment next to VECI label. 1985 3.7L-1V Light Duty Trucks All Models With Federal Emission Package (49 States) Consisting of: 1 - #611 Main Metering Jet PN 3837520 1 - Carburetor Air Horn Gasket PN 4267140 INSTRUCTIONS - Remove carburetor. - Remove air horn from carburetor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1651 FIGURE 10 - Main Metering Jet Location - Remove existing main metering jet (Figure 10). - Install #611 main metering jet PN 3837520. - Reinstall air horn with new air horn gasket PN 4267140. - Drill out concealment plug and prepare carburetor for propane idle set. - Per instructions in appropriate service manual, perform a propane idle set. Reset the propane/curb idle speeds to 775/750 for manuals and 800/775 for automatics. - Reset HFI to 1600 on Step 2. - Reset choke vacuum kick to 0.120". - Reset idle solenoid speed to 850 rpm (manual transmission) or 875 (automatic transmission). - Type in changes made on Emission Update Label and affix in engine compartment next to VECI label. 1985 5.2L-2V Light Duty Trucks All Models With "50 States" Emissions Packages Consisting of: 1 - Carburetor PN 4306453 1 - EGR Valve PN 4094891 1 - EGR Valve Gasket PN 4287938 1 - Carburetor Gasket PN 4095970 INSTRUCTIONS Using procedures as outlined in the appropriate service manual, perform the following: - Remove existing carburetor. - Install replacement carburetor PN 4306453 and gasket. - Remove EGR valve and scrape off old gasket material. - Install replacement EGR valve PN 4094891 and new gasket PN 4287938. - Start engine and check for leaks. - Check and reset if necessary, curb idle, fast idle to VECI label specifications. - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1652 1985 5.2L-2V Light Duty Trucks All Models With Federal Emissions Package (49 States) Consisting of: 2 - Main Metering Jet #147 PN 4271983 1 - EGR Valve PN 4287678 1 - EGR Valve Gasket PN 4287938 1 - Carburetor Base Gasket PN 4095970 INSTRUCTIONS Per instructions in appropriate service manual, perform the following: - Remove carburetor from engine. - Remove air horn from carburetor. FIGURE 11 - Holley 2280 Main Metering Jets - Remove existing main metering jet (Figure 11). - Install main metering jets provided, PN 4271983. - Adjust vacuum kick to 0.150". - Adjust mechanical unloader to 0.280". - Remove EGR valve and scrape off old gasket material. - Install new EGR valve PN 4287678 with new gasket PN 4287938. - Start engine, check for leaks. - Prepare carburetor for propane idle set and reinstall on engine using gasket PN 4095970. - Start engine and check for leaks. - Perform propane idle adjustment to 700 rpm (curb idle) and 770 rpm (propane enriched idle). - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. 5.9L-4V Light Duty Trucks All Automatic Models With Federal Emissions Package Consisting of: 1 - Carburetor PN 4342807 1 - EGR Valve PN 4287659 1 - Carburetor Base Gasket PN 3698365 1 - EGR Valve Gasket PN 4287938 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1653 INSTRUCTIONS - Remove existing carburetor. - Install new carburetor PN 4342807 along with new carburetor base gasket PN 3698365. - Raise the rear wheels of the vehicle with the transmission in neutral. Rotate the rear wheels through one revolution and determine the axle ratio. - If the vehicle has a 3.55 or 4.10 axle, replace EGR valve with PN 4287659 and gasket PN 4287938. - Start engine and check for leaks. - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. 5.9L-4V Light Duty Trucks All Manual Models With Federal Emission Package Consisting of: 1 - Carburetor PN 4342807 1 - Carburetor Base Gasket PN 3698365 INSTRUCTIONS - Remove original carburetor. - Install replacement carburetor PN 4342807 using new base gasket PN 3698365. - Start engine and check for leaks. - Type in changes made on Emission Update Label PN 4275084 and affix to engine compartment next to original VECI label. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1654 Air/Fuel Mixture: Technical Service Bulletins Propane Idle Adjustment - Determination Guidelines Models 1985 Model Year Vehicles Subject Guidelines For Determining the Use of Idle Mixture Adjustment Index FUEL Date 10/1/84 No.. 14-46-84 P-4283C This bulletin should serve as a guideline to help determine when a propane or "CO" method idle set is to be performed. The propane or "CO" method idle mixture adjustment should only be performed if it is determined necessary by the propane or "CO" method idle check in the respective year Driveability Test Procedure books or service manual. More specifically, propane or "CO" method idle mixture adjustment should only be used if an idle "problem" still exists after normal diagnosis has revealed no other faulty condition such as incorrect idle speed, incorrect basic ignition timing, faulty hose, or wire connections, etc. It is also important to make sure the EFC/ESA combustion computer system is operating properly. Adjustment of the idle mixture should also be performed after a major carburetor overhaul. A guideline of conditions for determining whether a propane or "CO" method idle set is needed is attached. The conditions listed below are affected by idle mixture adjustment: ^ Rough Idle Warm ^ Breakaway Sag-Light Throttle Tip In ^ Decel Die Out ^ After a Major Carburetor Overhaul The conditions listed below are not affected by idle mixture adjustment: ^ Spark Knock ^ Poor Fuel Economy ^ Road Load Surge ^ Decel Bucking ^ Long Cold Crank ^ Cold Start Die Out Time ^ After-Run (dieseling) ^ Lack of Power on ^ Cold Rough Idle Acceleration POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Adjustments > Idle Mixture and Speed Adjustments Air/Fuel Mixture: Adjustments Idle Mixture and Speed Adjustments 1981-86: Disconnect and plug canister control and EGR vacuum hoses. Remove PCV valve from grommet and allow it to draw underhood air. With ESC, ground carb switch and disconnect Oxygen sensor. 1981-82: Set idle speed screw to specification. Set cam to specified step. Set fast idle. 1983-88, 6 & 8 cyl. models with solenoids.: Turn A/C on, set blower to low, disconnect compressor clutch wire. Without A/C, apply battery voltage to solenoid. Adjust speed-up solenoid by removing adjusting screw and spring and inserting a one-eighth inch allen wrench into socket and turning. Set idle speed by adjusting screw on carb body. 1987-88 4cyl.: Energize radiator fan with a jumper wire. Remove PCV valve from grommet and disconnect vacuum kicker solenoid electrical lead. Disconnect oxygen sensor test connector on left fender shield. Adjust idle speed screw on top of solenoid to specified idle speed. Place fast idle cam on specified step and adjust to specified value. Disconnect idle solenoid electrical lead and set base idle to specified value. Other models: Set idle speed by turning screw on carb body. Set cam to specified step and adjust fast idle to specification. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Adjustments > Idle Mixture and Speed Adjustments > Page 1657 Air/Fuel Mixture: Adjustments Idle Mixture (Propane Method) Fig. 1 Propane enrichment specification chart 1985 HOLLEY 6280 CARBURETOR This procedure should only be used after normal diagnosis has revealed no other faults, or if carburetor has been overhauled. Idle mixture adjustment requires artificial propane enrichment. A propane enrichment tool, C-4464 or equivalent, must be used to adjust idle mixture. Before proceeding, make sure that propane cylinder is adequately filled to ensure correct propane flow. 1. Remove concealment plug cap from mixture adjusting screw. Refer to appropriate carburetor section. 2. Set parking brake and place transmission in Neutral position. 3. Turn off all lights and accessories, then connect tachometer. 4. Start engine and allow to reach normal operating temperature, then turn off engine. 5. Disconnect and plug the vacuum hose at the EGR valve and ESA computer. 6. Disconnect and plug canister purge hose at canister. 7. Disconnect carburetor ground switch and ensure switch is not grounded. 8. Disconnect and ground oxygen sensor electrical connector. 9. start engine and allow to run for at least four minutes. 10. Disconnect vacuum supply hose from choke diaphragm at the carburetor, then install propane hose in its place. 11. Remove PCV valve from cylinder head and allow to draw in underhood air. Ensure that propane cylinder remains upright during procedure. 12. Open main propane valve fully. Slowly open propane metering valve until maximum idle RPM is obtained. Too much propane will cause engine speed to drop. Adjust metering valve to obtain maximum idle RPM. 13. With propane flowing, adjust idle speed to specified enriched RPM, Fig. 1, by turning idle speed screw. 14. Adjust metering valve to obtain maximum RPM. If there has been a change in maximum RPM, readjust idle speed screw to specified enriched RPM. 15. Turn off main propane valve and allow engine speed to stabilize. 16. Adjust mixture screws to obtain smoothest idle at specified curb idle RPM, allowing time between adjustments for engine speed to stabilize. 17. Turn on main propane valve and adjust metering valve to obtain maximum engine RPM. If maximum engine speed differs by more than 25 RPM from specified enriched RPM, repeat steps 12 through 17. 18. When adjustment is correct, turn off both propane valves, stop engine and remove tool. 19. Install new concealment plug, then connect oxygen sensor electrical connector. 20. Connect vacuum line at ESA, then perform ``Curb Idle Speed, Adjust'' and ``Fast Idle Speed, Adjust'' procedures. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package Technical Service Bulletin # 250485 Date: 850506 High Altitude Conversion Package Models 1985 Light Duty Domestic Trucks Subject High Altitude Conversion Packages & Adjustment for Improved Engine Performance Index EMISSIONS Date May 6, 1985 No.. 25-04-85 P-1522-C Packages are now available to accommodate a customer who wishes to convert his 1985 low altitude vehicle for improved high altitude (over 4,000 feet above sea level) engine performance. Vehicles with the low altitude package transferred to service in high altitude areas may exhibit undesirable driveability. However, the installation of a high altitude conversion package is voluntary and at the customer's expense. The high altitude field conversion packages and procedures outlined below have been authorized on the following 1985 non-altitude equipped engine families in service at altitudes above 4,000 feet above sea level. CONVERSION INSTRUCTIONS Sea Level to Altitude FIGURE 1 - Vehicle Emission Control Information Label IMPORTANT: IN SOME OF THE CONVERSION PROCEDURES YOU WILL BE REQUIRED TO INSTALL A NEW VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL PN 4275084. THIS LABEL HAS TWO AREAS THAT ARE IMPACT IMPRINTABLE WITH A TYPEWRITER (SEE FIGURE 1). If you are required to readjust timing, curb idle speed, or fast idle speed to a specification different than the original VECI label specification, then just type in the new specification after the subject operation. If you are asked to refer to the original VECI label specifications, type in on the right hand side of the label "Refer to Original VECI Label." Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1662 In every case where this label is used, type in after - AUTHORITY OF Technical Service Bulletin #25-04-85, and your dealer code below. Label PN 4275084 is available from Parts Supply. FIGURE 2 - Vehicle Emission Control Information Label The engine family chart below will help identify the appropriate parts to be installed by recording body style and engine family from the original VECI label. This chart cross references the EPA engine family with the engine application used in the accompanying instructions (refer to Figure 2). EPA Engine Family Engine Application (Found on VECI Label) 2.2L-2V Federal FCR2.2T2AAB6 2.2L-2V 50 States FCR2.2T2HBM9 2.6L-2V Federal FCR2.6T2AAB8 3.7L-1V Federal FCR3.7T1BBA0 5.2L-2V 50 States FCR5.2T2HBN1 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1663 5.2L-2V Federal FCR5.2T2BBF6 5.9L-4V Federal FCR5.9T4BBF1 POLICY: Information only 1985 2.2L-2V Light Duty Trucks All Models With Federal Emissions Package (49 States) Dodge Ram Van, Dodge Caravan, Plymouth Voy Consisting of: 1 - #211 Primary Main Jet PN 4293797 1 - #215 Secondary Main Jet PN 4240006 1 - #180 Primary High Speed Bleed PN 4342920 1 - #210 Secondary High Speed Bleed PN 4342921 1 - Carburetor Air Horn Gasket PN 4293846 INSTRUCTIONS FIGURE 1. Holley 5220 Primary Main Metering Jet #211 FIGURE 2. Holley 5220 Secondary Main Metering Jet #223 - Remove carburetor air horn. - Remove primary and secondary main metering jets. Refer to Figures 1 and 2. - Install #211 primary main metering jet PN 4293797. - Install #215 secondary main metering jet PN 4240006. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1664 FIGURE 3. Holley 5220 Primary High Speed Bleed #180 FIGURE 4. Holley 5220 Secondary High Speed Bleed #210 - Remove primary and secondary high speed bleeds. Refer to Figures 3 and 4. - Install #180 primary high speed bleed PN 4342920. - Install #210 secondary high speed bleed PN 4342921. FIGURE 5. Holley 5220 Power Valve Location - Turn power valve (Figure 5) two full turns counterclockwise (lean). - Reinstall air horn with new air horn gasket PN 4293846. Start engine and check for leaks. - Warm up engine and set idle speed to that specified on the VECI label. - Type in changes made on Emission Update Label PN 4275084 and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1665 1985 2.2L-2V Light Duty Truck Dodge Ram Van, Dodge Caravan & Plymouth Voyager Only Equipped With "50 States" Emission Package Consisting of: 1 - Carburetor (manual or automatic PN 4342891 transmission) Also order conversion hardware package. 1 - Hardware Package PN 4342950 Consisting of: 1 - Carburetor Base Gasket PN 4095975 1 - H.A.C. PN 4306202 1 - Hose Routing Diagram NPN 1 - Mounting Bracket (H.A.C.) PN 4105199 1 - H.A.C. Hose Harness NPN 3 - Mounting Screws NPN INSTRUCTIONS - Remove carburetor per instructions in appropriate engine performance/electrical shop manual. - Install new carburetor with new base gasket. FIGURE 6 - High Altitude Compensator Mounting - Install altitude compensator with bracket (Figure 6). - Install altitude compensator vacuum hose harness, route as shown in hose routing diagram (Figure 6). - Warm up engine. - Set engine idle speed to specified VECI label specification. - Set high fast idle on Step 3 (lowest) to specification. - Double check hose routing and installation of fuel lines. - Type in changes made on the Emission Update Label PN 4275084 and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1666 1985 2.6L-2V Light Duty Truck All Models With Federal Emissions Package (49 States) Consisting of: 1 - Carburetor Jet Kit PN MD088294 containing: #110 Primary Main Jet #175 Secondary Main Jet #100 Primary Air Bleed Jet #120 Secondary Air Bleed Jet 1 - Float Chamber Cover Gasket PN MD608639 1 - Choke Cover Screw Kit PN MD606977 1 - Carburetor Flange Gasket PN MD025344 INSTRUCTIONS - Remove carburetor from engine and take off air horn per instructions in appropriate service manual. FIGURE 7 - Mikuni Jet Locations - Remove primary and secondary main jets as shown in Figure 7. - Install #110 primary main jet and #175 secondary main jet in the primary and secondary pedestals. - Reinstall air horn on carburetor using new air horn gasket PN MD608639 and choke cover screw kit PN MD606977. FIGURE 8 - Mikuni Air Bleed Jet Locations - Remove primary and secondary air bleed jets shown in Figure 8. - Prepare carburetor for propane idle set by drilling out concealment plug. - Install #120 secondary air bleed jet and #100 primary air bleed jet. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1667 - Reinstall carburetor on engine using a new carburetor flange gasket, PN MD025344. - Remove vacuum controlled orificed tank vapor valve (VCOTV) and the vacuum/line(s) to the valve. - Remove the 3/16" tank vent line from the vapor canister and replace with 24" of 3/16" tank vent line and route directly to steel tank vent tube. - Remove the manifold vacuum line from the manifold vacuum tee (originally to the VCOTV) and cap the tee. - Remove the EGR delay valve at the corresponding EGR and carburetor ports and replace with 8" of bulk 3/16" vacuum line from stock. - Start engine and warm up to operating temperature. - Set idle rpm (curb) to 850 rpm and propane enriched rpm to 950 rpm. - Set throttle kicker rpm to 1050 rpm. FIGURE 9 - Authorized Modifications Label - Type in changes made on Authorized Modification Label, PN 4275086 (Figure 9), and affix to engine compartment next to VECI label. 1985 3.7L-1V Light Duty Trucks All Models With Federal Emission Package (49 States) Consisting of: 1 - #611 Main Metering Jet PN 3837520 1 - Carburetor Air Horn Gasket PN 4267140 INSTRUCTIONS - Remove carburetor. - Remove air horn from carburetor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1668 FIGURE 10 - Main Metering Jet Location - Remove existing main metering jet (Figure 10). - Install #611 main metering jet PN 3837520. - Reinstall air horn with new air horn gasket PN 4267140. - Drill out concealment plug and prepare carburetor for propane idle set. - Per instructions in appropriate service manual, perform a propane idle set. Reset the propane/curb idle speeds to 775/750 for manuals and 800/775 for automatics. - Reset HFI to 1600 on Step 2. - Reset choke vacuum kick to 0.120". - Reset idle solenoid speed to 850 rpm (manual transmission) or 875 (automatic transmission). - Type in changes made on Emission Update Label and affix in engine compartment next to VECI label. 1985 5.2L-2V Light Duty Trucks All Models With "50 States" Emissions Packages Consisting of: 1 - Carburetor PN 4306453 1 - EGR Valve PN 4094891 1 - EGR Valve Gasket PN 4287938 1 - Carburetor Gasket PN 4095970 INSTRUCTIONS Using procedures as outlined in the appropriate service manual, perform the following: - Remove existing carburetor. - Install replacement carburetor PN 4306453 and gasket. - Remove EGR valve and scrape off old gasket material. - Install replacement EGR valve PN 4094891 and new gasket PN 4287938. - Start engine and check for leaks. - Check and reset if necessary, curb idle, fast idle to VECI label specifications. - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1669 1985 5.2L-2V Light Duty Trucks All Models With Federal Emissions Package (49 States) Consisting of: 2 - Main Metering Jet #147 PN 4271983 1 - EGR Valve PN 4287678 1 - EGR Valve Gasket PN 4287938 1 - Carburetor Base Gasket PN 4095970 INSTRUCTIONS Per instructions in appropriate service manual, perform the following: - Remove carburetor from engine. - Remove air horn from carburetor. FIGURE 11 - Holley 2280 Main Metering Jets - Remove existing main metering jet (Figure 11). - Install main metering jets provided, PN 4271983. - Adjust vacuum kick to 0.150". - Adjust mechanical unloader to 0.280". - Remove EGR valve and scrape off old gasket material. - Install new EGR valve PN 4287678 with new gasket PN 4287938. - Start engine, check for leaks. - Prepare carburetor for propane idle set and reinstall on engine using gasket PN 4095970. - Start engine and check for leaks. - Perform propane idle adjustment to 700 rpm (curb idle) and 770 rpm (propane enriched idle). - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. 5.9L-4V Light Duty Trucks All Automatic Models With Federal Emissions Package Consisting of: 1 - Carburetor PN 4342807 1 - EGR Valve PN 4287659 1 - Carburetor Base Gasket PN 3698365 1 - EGR Valve Gasket PN 4287938 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1670 INSTRUCTIONS - Remove existing carburetor. - Install new carburetor PN 4342807 along with new carburetor base gasket PN 3698365. - Raise the rear wheels of the vehicle with the transmission in neutral. Rotate the rear wheels through one revolution and determine the axle ratio. - If the vehicle has a 3.55 or 4.10 axle, replace EGR valve with PN 4287659 and gasket PN 4287938. - Start engine and check for leaks. - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. 5.9L-4V Light Duty Trucks All Manual Models With Federal Emission Package Consisting of: 1 - Carburetor PN 4342807 1 - Carburetor Base Gasket PN 3698365 INSTRUCTIONS - Remove original carburetor. - Install replacement carburetor PN 4342807 using new base gasket PN 3698365. - Start engine and check for leaks. - Type in changes made on Emission Update Label PN 4275084 and affix to engine compartment next to original VECI label. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 1671 Idle Speed: Technical Service Bulletins Propane Idle Adjustment - Determination Guidelines Models 1985 Model Year Vehicles Subject Guidelines For Determining the Use of Idle Mixture Adjustment Index FUEL Date 10/1/84 No.. 14-46-84 P-4283C This bulletin should serve as a guideline to help determine when a propane or "CO" method idle set is to be performed. The propane or "CO" method idle mixture adjustment should only be performed if it is determined necessary by the propane or "CO" method idle check in the respective year Driveability Test Procedure books or service manual. More specifically, propane or "CO" method idle mixture adjustment should only be used if an idle "problem" still exists after normal diagnosis has revealed no other faulty condition such as incorrect idle speed, incorrect basic ignition timing, faulty hose, or wire connections, etc. It is also important to make sure the EFC/ESA combustion computer system is operating properly. Adjustment of the idle mixture should also be performed after a major carburetor overhaul. A guideline of conditions for determining whether a propane or "CO" method idle set is needed is attached. The conditions listed below are affected by idle mixture adjustment: ^ Rough Idle Warm ^ Breakaway Sag-Light Throttle Tip In ^ Decel Die Out ^ After a Major Carburetor Overhaul The conditions listed below are not affected by idle mixture adjustment: ^ Spark Knock ^ Poor Fuel Economy ^ Road Load Surge ^ Decel Bucking ^ Long Cold Crank ^ Cold Start Die Out Time ^ After-Run (dieseling) ^ Lack of Power on ^ Cold Rough Idle Acceleration POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 1672 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Idle Mixture and Speed Adjustments Idle Speed: Adjustments Idle Mixture and Speed Adjustments 1981-86: Disconnect and plug canister control and EGR vacuum hoses. Remove PCV valve from grommet and allow it to draw underhood air. With ESC, ground carb switch and disconnect Oxygen sensor. 1981-82: Set idle speed screw to specification. Set cam to specified step. Set fast idle. 1983-88, 6 & 8 cyl. models with solenoids.: Turn A/C on, set blower to low, disconnect compressor clutch wire. Without A/C, apply battery voltage to solenoid. Adjust speed-up solenoid by removing adjusting screw and spring and inserting a one-eighth inch allen wrench into socket and turning. Set idle speed by adjusting screw on carb body. 1987-88 4cyl.: Energize radiator fan with a jumper wire. Remove PCV valve from grommet and disconnect vacuum kicker solenoid electrical lead. Disconnect oxygen sensor test connector on left fender shield. Adjust idle speed screw on top of solenoid to specified idle speed. Place fast idle cam on specified step and adjust to specified value. Disconnect idle solenoid electrical lead and set base idle to specified value. Other models: Set idle speed by turning screw on carb body. Set cam to specified step and adjust fast idle to specification. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Idle Mixture and Speed Adjustments > Page 1675 Idle Speed: Adjustments Idle Speed Adjustment Curb Idle Speed Adjustment 1. Disconnect and plug vacuum hose at EGR valve, ESA module, distributor or carburetor, as required. 2. On models equipped with carburetor ground switch, connect jumper wire between switch and ground. 3. On models not equipped with Spark Control Computer (SCC), disconnect and plug vacuum hose from carburetor at heated air temperature sensor and Orifice Spark Advance Control (OSAC) valve, if equipped. 4. On all models, disconnect and plug control hose at canister. 5. Remove PCV valve from cylinder head cover and allow to draw underhood air. 6. Connect tachometer, then start engine and allow to reach normal operating temperature. 7. On models less 1985 6280 carburetor, adjust Solenoid Idle Stop (SIS), if equipped, as follows: a. On 1983-84 models with A/C, turn on A/C and set blower on low, then disconnect A/C clutch wire. b. On 1983-84 models less A/C and all 1985-87 models, connect jumper wire between battery positive terminal and the SIS lead wire. Ensure correct jumper wire installation. Applying battery voltage to other than correct wire will damage the wiring harness. c. On all models, open throttle slightly to allow solenoid plunger to extend. d. On Holley models, remove adjusting screw and spring from solenoid, then insert 1/8 inch Allen wrench into the solenoid and adjust to correct engine RPM. e. On Carter models, turn adjusting screw on throttle lever to obtain correct engine RPM. f. On Rochester models, turn solenoid plunger screw to obtain correct engine RPM. g. Turn off A/C and reconnect clutch wire or remove jumper, if equipped. h. Install solenoid screw and spring, if equipped with Holley carburetor. 8. On models with 1985 6280 carburetor, adjust Solenoid Idle Stop (SIS) as follows: a. Disconnect and ground engine harness electrical connector from oxygen sensor. b. Allow engine to run at least five minutes, then connect a jumper wire between the battery positive terminal and SIS lead wire. Ensure correct jumper wire installation. Applying battery voltage to other than correct wire will damage the wiring harness. c. Open throttle slightly to allow solenoid plunger to extend. d. Remove adjusting screw and spring from solenoid, then insert a 1/8 inch allen wrench into the solenoid and adjust to correct engine RPM. e. Install screw and spring, then turn in screw until it bottoms out. 9. On 1983-84 models equipped with oxygen sensor feedback carburetors, proceed as follows: a. Disconnect electrical connector from oxygen sensor and ground connector. b. Remove and plug vacuum hose at vacuum transducer on SCC, then install suitable vacuum pump to vacuum transducer and apply 16 inches of vacuum. c. Allow engine to run for two minutes. If idle is not as specified, turn adjusting screw on solenoid to obtain correct RPM. 10. On 1983-84 models not equipped with oxygen sensor feedback carburetors and all 1985-87 model carburetors, proceed as follows: a. Allow engine to run for one minute. b. If idle RPM is not as specified, turn idle speed screw to obtain correct RPM. 11. On all models, turn off engine, connect vacuum lines and remove tachometer. Remove jumper wire and connect oxygen sensor electrical connector, if equipped. After step 11 has been completed, idle speed may change slightly. This condition is normal and engine speed should not be readjusted. Fast Idle Adjustment 1. Disconnect and plug vacuum hose at EGR valve, ESA computer and distributor, if equipped. 2. On models equipped with carburetor ground switch, connect jumper wire between switch and ground. 3. On models not equipped with Spark Control Computer (SCC), disconnect and plug vacuum hose from carburetor at heated air temperature sensor. 4. On all models, disconnect and plug control hose at canister. 5. Remove PCV valve from cylinder head cover and allow to draw underhood air. 6. Connect tachometer, then start engine and allow to reach normal operating temperature. 7. On models equipped with oxygen sensor feedback, disconnect electrical connector from oxygen sensor and ground connector, then allow engine to run for two minutes. 8. On models not equipped with oxygen sensor feedback, allow engine to run for one minute. 9. On all models, open throttle slightly and position fast idle adjusting screw on second highest step of fast idle cam. 10. Open choke fully, then adjust fast idle speed screw to obtain specified RPM. 11. Return to idle, then reposition adjusting screw on second highest step of fast idle cam to ensure correct RPM. Readjust if necessary. 12. Turn off engine, then connect vacuum hoses and remove tachometer. Remove jumper wire and connect oxygen sensor electrical connector, if equipped. After step 12 has been completed, idle speed may change slightly. This condition is normal and engine speed should not be readjusted. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1684 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1685 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1686 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1687 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1688 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1689 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1690 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1691 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1692 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1693 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1694 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1695 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1696 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1697 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1698 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1704 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1705 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1706 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1707 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1708 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1709 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1710 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1711 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1712 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1713 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1714 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1715 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1716 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1717 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1718 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Timing Marks and Indicators: Diagrams TIMING MARK 1981-85 5.2L & 5.9L Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams > Page 1729 TIMING MARK 1981-90 Some 5.2L & 5.9L Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Service and Repair Ignition Cable: Service and Repair REMOVAL AND INSTALLATION Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (1/2 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. Engine Firing Order Install cables into the proper engine cylinder firing order. When replacing the spark plug and coil cables, route the cables correctly and secure in the proper retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also cause cross ignition of the plugs or short circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made between the plug cable and the distributor cap tower. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Vacuum Advance Unit <--> [Distributor Advance Unit] > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Vacuum Advance Unit <--> [Distributor Advance Unit] > Component Information > Specifications > Page 1737 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Vacuum Control > Component Information > Locations Distributor Vacuum Control: Locations Orifice Spark Advance Control (OSAC) Valve Location. In Air Cleaner Housing Applicable to: V8 Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Check Specifications Compression Check Specifications Compression Pressure 100 psi At cranking speed, engine temperature normalized, throttle Note: Minimum open Maximum Variation 25 psi Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Adjustments Valve Clearance: Adjustments 1981-87 6-225 (3.7L) & ALL 1980-87 V8 ENGINES These engines are equipped with hydraulic lifters. No provision for adjustment is provided. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Charge Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Charge Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 1754 Charge Temperature Switch Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Charge Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 1755 Charge Temperature Sensor: Description and Operation Fig. 4 Switches & sensors location. V8 engine The CTS, Fig. 4, is used on eight cylinder engines and is located in the intake manifold No. 8 runner on eight cylinder engines. When the incoming air fuel mixture is below 60° F., the CTS will close, allowing no EGR timer function, no EGR valve operation and the air injection directed upstream into the exhaust manifold. When incoming air-fuel mixture is above 60° F., the CTS will open allowing EGR timer to expire, the EGR valve to operate and air injection switched downstream into the exhaust system. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Charge Temperature Switch <--> [Intake Air Temperature Switch] > Component Information > Locations Charge Temperature Switch: Locations Engine Mounted Switches & Sensors. Upper RH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1763 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1768 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 1773 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations Coolant Temperature Sensor/Switch (For Computer): Component Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 1776 Coolant Temperature Sensor/Switch (For Computer): Connector Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 1777 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Coolant Temperature Switch Coolant Temperature Sensor/Switch (For Computer): Description and Operation Coolant Temperature Switch Fig. 4 Switches & sensors location. V8 engine On V8 engines the coolant switch is located on the front of the intake manifold, Fig. 4. It operates by supplying a signal to the computer when the engine coolant temperature is below 150~ F. This information is required to prevent a change in air fuel ratio until engine operation temperature is reached except there is no control of canister purging. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Coolant Temperature Switch > Page 1780 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Description The coolant temperature sensor measures temperature of the engine coolant. The coolant temperature sensor is mounted in the thermostat housing or in water passage of intake manifold. The sensor monitors engine coolant (operating) temperature. It supplies the logic module with a voltage signal which varies with coolant temperature. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1785 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control Crankshaft Position Sensor: Service and Repair RWD W/ Electronic Spark Control Removal & Installation Removal 1. Disconnect vacuum line at distributor, if equipped. 2. Disconnect distributor pickup lead(s) at wiring harness connector, then remove distributor cap. 3. Mark position of rotor on distributor body and engine block surface so that distributor can be installed in the same position. 4. Remove hold-down and/or bolt and lift distributor from engine. Installation 1. If engine was cranked after distributor was removed from engine, rotate crankshaft to bring No. 1 piston up on its compression stroke and align timing mark on crankshaft pulley with ``O'' (TDC) mark on timing cover. 2. With distributor gasket or O-ring in place, hold distributor over mounting pad. 3. Turn rotor to a position just ahead of the No. 1 distributor cap terminal. 4. Install distributor, engaging distributor gear with camshaft drive gear on 6 cylinder engines. On V-8 engines, engage tang of distributor shaft with slot in oil pump drive gear. With distributor fully seated on engine, rotor should be under No. 1 cap terminal. 5. Install distributor hold-down and/or bolt, distributor cap, pickup lead(s) and vacuum line. 6. Adjust ignition timing to specifications found in the Tune Up section. Distributor Shaft & Bushing Wear Test 1. Remove distributor from vehicle and clamp distributor in a vise. Use extreme caution not to damage distributor. 2. Attach a dial indicator to housing so plunger rests against reluctor sleeve. 3. Place a wire loop around reluctor sleeve and hook a spring scale on the other end of the loop. Apply a 1-1/2 lb. pull toward dial indicator. Apply a 1 lb. pull away from dial indicator and read movement on indicator. 4. Movement must not exceed .006 inch. If movement exceeds limit, replace either housing or shaft to bring movement back within tolerance. Distributor Disassembly 1. Remove rotor and vacuum advance unit, if equipped Fig. 14. 2. Remove reluctor by prying up from bottom of reluctor using two screwdrivers with a maximum blade width of 7/16 in. Use care not to damage or distort reluctor teeth. 3. Remove two screws and lockwashers attaching lower plate to distributor housing, then lift out lower plate, upper plate and pickup coil as an assembly. Do not remove distributor cap clamp springs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 1788 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 4. On eight cylinder units, if distributor housing, shaft, reluctor sleeve or governor weights are to be replace, proceed as follows: a. Remove distributor shaft retaining pin and slide retainer off end of shaft. b. If necessary, use a file to clean burrs from around pin hole area on shaft, then remove lower thrust washer. c. Push shaft upward and remove from distributor housing. Distributor Assembly Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 1789 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 1. Lubricate and test operation of governor weights. Inspect weight springs for distortion and bearing surfaces and pins for damage. 2. Lubricate upper thrust washer and install onto shaft. Install shaft into housing. 3. On eight cylinder units, install distributor shaft retainer and pin, Fig. 14. 4. On all units, install lower plate, upper plate and pickup coil assembly. 5. Attach vacuum advance unit to pickup plate, then install vacuum advance unit attaching screws and washers. 6. Position reluctor keeper pin into place on reluctor sleeve, then slide reluctor down reluctor sleeve and press firmly into position. Install keeper pin. 7. Lubricate felt pad located in top of reluctor sleeve with one drop of light engine oil, then install rotor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 1790 Crankshaft Position Sensor: Service and Repair RWD W/O Electronic Spark Control Removal & Installation Removal 1. Disconnect vacuum line at distributor, if equipped. 2. Disconnect distributor pickup lead(s) at wiring harness connector, then remove distributor cap. 3. Mark position of rotor on distributor body and engine block surface so that distributor can be installed in the same position. 4. Remove hold-down and/or bolt and lift distributor from engine. Installation 1. If engine was cranked after distributor was removed from engine, rotate crankshaft to bring No. 1 piston up on its compression stroke and align timing mark on crankshaft pulley with ``O'' (TDC) mark on timing cover. 2. With distributor gasket or O-ring in place, hold distributor over mounting pad. 3. Turn rotor to a position just ahead of the No. 1 distributor cap terminal. 4. Install distributor, engaging distributor gear with camshaft drive gear on 6 cylinder engines. On V-8 engines, engage tang of distributor shaft with slot in oil pump drive gear. With distributor fully seated on engine, rotor should be under No. 1 cap terminal. 5. Install distributor hold-down and/or bolt, distributor cap, pickup lead(s) and vacuum line. 6. Adjust ignition timing to specifications found in the Tune Up section. Distributor Shaft & Bushing Wear Test 1. Remove distributor from vehicle and clamp distributor in a vise. Use extreme caution not to damage distributor. 2. Attach a dial indicator to housing so plunger rests against reluctor sleeve. 3. Place a wire loop around reluctor sleeve and hook a spring scale on the other end of the loop. Apply a 1-1/2 lb. pull toward dial indicator. Apply a 1 lb. pull away from dial indicator and read movement on indicator. 4. Movement must not exceed .006 inch. If movement exceeds limit, replace either housing or shaft to bring movement back within tolerance. Distributor Disassembly 1. Remove rotor and vacuum advance unit, if equipped Fig. 14. 2. Remove reluctor by prying up from bottom of reluctor using two screwdrivers with a maximum blade width of 7/16 in. Use care not to damage or distort reluctor teeth. 3. Remove two screws and lockwashers attaching lower plate to distributor housing, then lift out lower plate, upper plate and pickup coil as an assembly. Do not remove distributor cap clamp springs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 1791 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 4. On eight cylinder units, if distributor housing, shaft, reluctor sleeve or governor weights are to be replace, proceed as follows: a. Remove distributor shaft retaining pin and slide retainer off end of shaft. b. If necessary, use a file to clean burrs from around pin hole area on shaft, then remove lower thrust washer. c. Push shaft upward and remove from distributor housing. Distributor Assembly Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 1792 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 1. Lubricate and test operation of governor weights. Inspect weight springs for distortion and bearing surfaces and pins for damage. 2. Lubricate upper thrust washer and install onto shaft. Install shaft into housing. 3. On eight cylinder units, install distributor shaft retainer and pin, Fig. 14. 4. On all units, install lower plate, upper plate and pickup coil assembly. 5. Attach vacuum advance unit to pickup plate, then install vacuum advance unit attaching screws and washers. 6. Position reluctor keeper pin into place on reluctor sleeve, then slide reluctor down reluctor sleeve and press firmly into position. Install keeper pin. 7. Lubricate felt pad located in top of reluctor sleeve with one drop of light engine oil, then install rotor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Module <--> [Electronic Spark Control Module] > Component Information > Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Module <--> [Electronic Spark Control Module] > Component Information > Locations > Page 1796 Power Module: Description and Operation The spark control computer controls the air fuel ratio of the carburetor and the ignition timing. The computer receives signals from various sensors and processes them to determine the air fuel ratio of the carburetor and ignition timing. There are as many as six types of sensors which can be used to supply the spark control computer with the necessary information needed to fire the spark plugs at the precise moment and, with the feedback carburetor, change the air-fuel ratio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1805 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1806 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1807 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1808 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1809 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1810 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1811 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1812 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1813 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1814 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1815 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1816 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1817 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1818 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1819 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock Technical Service Bulletin # 181985A Date: 851201 Fuel System - Vapor Lock Models 1981-1985 Van & Wagon Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 20, 1985 No. 18-19-85 REVISION A P-4782-C This bulletin supersedes Technical Service Bulletin #18-19-85 which should be removed from your files. The model application has been expanded to include 1981 and 1982 model years. SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING TWO PART NUMBERS: Vapor Lock Package With 22 Gallon Fuel Tank PN 4397611 Vapor Lock Package With 36 Gallon Fuel Tank PN 4397612 ADDITIONAL PARTS INFORMATION ON NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 All vehicles equipped with dual air conditioning, without electrically heated rear window defroster, and with 60 amp alternator must order the following package in addition to the vapor lock package. If vehicle is equipped with a 114 amp alternator, do not order this package or make any changes to the charging system. 1 78 AMP Alternator Package PN 4397615 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1824 Refer to parts list for contents of each package. Must be ordered separately: 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. REPAIR PROCEDURE A.Engine Compartment Harness Pn 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1A - ENGINE COMPARTMENT WIRING 3. Remove engine cover. Install the bare eyelet terminal of overlay harness, PN 4362295, to the negative terminal of the ignition coil as shown in Figure 1-A. FIGURE 1B - ENGINE COMPARTMENT WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1825 4. Route and secure the engine overlay harness, PN 4362295, along the existing main engine wiring harness using the existing wiring clips and two tie wraps, PN 6015756 (Figure 1-B). FIGURE 1C - ENGINE COMPARTMENT WIRING 5. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness to the bulkhead connector using the existing wiring clips and three tie wraps, PN 6015756 (Figure 1-C). Loop and tape any excess wire of the engine overlay harness. FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 6. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar multi-purpose grease PN 4318063, and snap into cavity #14 of the engine side of the bulkhead connector (Figure 1-D). B.Instrument Panel Harnesses Pn 4362289, All Models Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1826 FIGURE 2A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) 1. Remove instrument panel left lower trim panel. 2. Insert two bare terminals from instrument panel overlay harness, PN 4362289, into the instrument panel side of the bulkhead connector (Figure 2-A). a. Gray with black tracer wire into cavity #14. b. Dark green wire into cavity #13. INSTRUMENT PANEL WIRING 3. Secure bare eyelet ground terminal (white with black tracer wire) from instrument panel overlay harness, PN 4362289, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). NOTE: CERTAIN VEHICLES ARE ALREADY EQUIPPED WITH THE GROUND SCREW. IF SO, DISCARD THE SUPPLIED SCREW. FIGURE 2C - INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1827 FIGURE 2D - INSTRUMENT PANEL WIRING 4. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-C). Install the extracted terminal (orange wire) into the natural colored 1-way connector supplied with instrument panel overlay harness, PN 4362289. Install the bare terminal (orange wire) from the instrument panel overlay harness, PN 4362289, into the vacated cavity in the ignition switch connector. Reconnect the natural colored 1-way connectors supplied with the instrument panel overlay harness, PN 4362289, and reconnect the ignition switch connectors (Figure 2-C and 2-D). FIGURE 2E - TYPICAL CONTROL MODULE MOUNTING 5. Connect the control (auto shut-down) module, PN 5226640, to the natural colored 8-way connector from instrument panel overlay harness, PN 4362289. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1828 FIGURE 2D - INSTRUMENT PANEL WIRING FIGURE 2F - INSTRUMENT PANEL WIRING 6. Route the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289, to the back of the brake bracket for mating in a later step (Figures 2-B, 2-D, and 2-F). Secure instrument panel overlay harness, PN 4362289, using tie wrap, PN 6015756, to keep it clear of any possible interferences. Only one of the following installation procedures (Step 7) will be used. Take notice of which one applies to the vehicle being repaired. 7. Without Auxiliary Air Conditioning and/or Heater - Jumper Harness PN 4362291 a. Remove instrument panel hood and bezel assembly and remove radio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1829 FIGURE 2D - INSTRUMENT PANEL WIRING b. Route instrument panel jumper harness, PN 4362291, from the back of the brake bracket to the existing 3-way red molded connector. Secure by using existing wiring clips (Figure 2-D). c. Insert the bare bullet terminal (black with white tracer wire) from instrument panel jumper harness, PN 4362291, into the existing 3-way red molded connector from the main instrument panel wiring harness (Figure 2-D). d. Mate the orange colored 1-way connector from instrument panel jumper harness, PN 4362291, to the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). e. Reinstall instrument panel hood and bezel assembly and install radio. FIGURE 2F - INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater and Power Windows - Jumper Harness PN 4362292 a. Disconnect from each other, the two existing brown colored 1-way connectors located near the left instrument panel vent (Figure 2-F). Reconnect these two brown colored 1-way connectors to the two brown colored 1-way connectors from instrument panel jumper harness, PN 4362292 (Figure 2-F). b. Mate the orange colored 1-way connector from the instrument panel jumper harness, PN 4362292, to the orange colored 1-way connector from instrument panel overlay harness, PN 4362289 (Figure 2-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1830 INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater Without Power Windows - Relay Harness PN 4362290 a. Remove instrument panel hood and bezel assembly. Remove radio. b. Install the ignition switch protection relay, PN 4162597, to the back of the brake bracket (mounting location shown in Figure 2-B) and attach instrument panel relay harness, PN 4362290, to relay. c. Secure bare eyelet ground terminal (white wire) from instrument panel relay harness, PN 4362290, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING d. Route the dark blue wire from the instrument panel relay harness, PN 4362290 to the existing 3-way red molded connector using existing wiring clips. Insert bullet terminal (dark blue wire) into red molded connector (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1831 INSTRUMENT PANEL WIRING e. Insert bare bullet terminal (red wire) from instrument panel relay harness, PN 4362290, into the existing 3-way yellow molded connector from the main instrument panel wiring harness (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING f. Mate the orange colored 1-way connector from instrument panel relay harness, PN 4362290, to the colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). g. Install the instrument panel left lower trim panel, instrument panel hood, bezel assembly and radio. C.In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Feed red and yellow molds of body wiring harness, PN 4362293, through slot in the crossmember. Remove existing screw for gauge unit ground. Install eyelet terminal of harness, PN 4362293 (and ground eyelet terminal of 36 gallon tank gauge/pump unit) and torque ground screw to 36 inch pounds. CAUTION: GROUND SCREW MUST BE TIGHTENED SECURELY TO OPERATE ELECTRIC PUMP AND GAUGE UNIT. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1832 FIGURE 3A - BODY WIRING FIGURE 3B - BODY WIRING Install red mold of body harness, PN 4362293, onto red stud of gauge/pump unit. Install yellow mold of harness, PN 4362293, onto black stud of gauge/pump unit (figure 3-a or 3-b). Install molded blade terminal of harness, PN 4362293, onto blade terminal of 22 gallon gauge unit only. NOTE: PREVIOUS GAUGE UNIT GROUND WILL NOT BE USED ON 22 GALLON GAUGE/PUMP UNIT. ON 36 GALLON GAUGE PUMP UNIT, THE GROUND WIRE ON HARNESS PN 4362293 WILL NOT BE USED. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. Set aside the rest of harness, PN 4362293, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. D.Body Wiring Harness Pn 4362293 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1833 FIGURE 3C - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1834 FIGURE 3-F - BODY WIRING 1. Vehicles With 36 Gallon Tank Route harness, PN 4362293, to the right (passenger) side of vehicle along the fuel line tubes and tie wrap (1). At right frame rail, route harness forward to next crossmember (Figures 3-C and 3-E). Tie wrap harness in three (3) places. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1835 FIGURE 3D - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1836 FIGURE 3-F - BODY WIRING Vehicles With 22 Gallon Tank Route harness, PN 4362293, along right frame rail following brake lines (Figures 3-D and 3-E). Tie wrap in two (2) places. NOTE: HARNESS MUST BE ABOVE SHOCK STRUT WITH EITHER 36 OR 22 GALLON TANK. 2. At crossmember, route harness to the left rail following existing brake lines and tie wrap in two (2) places. At left rail, route harness forward through access holes following existing brake lines. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1837 FIGURE 3-F - BODY WIRING NOTE: HARNESS SHOULD BE TIGHT IN THIS AREA THE WRAP IN FOUR (4) PLACES (FIGURE 3-E). 3. At engine compartment, route harness through existing speedometer cable clips to bulkhead connector. If excess wiring exists; loop, tie wrap (2), and install into existing clip (Figure 3-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1838 FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 4. Plug bare terminal of harness, PN 4362293, into cavity #13 of the bulkhead connector (Figure 1-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1839 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1840 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1841 FIGURE 9 - ELECTRIC FUEL PUMP WIRING DIAGRAMW/AUX A/C & HEATER-W/O POWER WINDOWS 5. For all vehicles except those which require a 78 amp alternator package: Reinstall instrument panel side, then engine compartment side of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURES 7, 8, OR 9 FOR OVERALL WIRING DIAGRAMS. E.Engine Compartment Fuel Reservoir/Filter Lnstallation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1842 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER 1. Using template, PN 4418011, mark and drill (from engine side of passenger side chassis rail) two (2) holes .290" diameter (L size drill) as shown in Figure 4-A. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1843 FIGURE 4B - Mounting Fuel Resevoir/Filter 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. NOTE: RUBBER SPLASH SHIELD MAY HAVE TO BE CUT OUT AROUND FUEL RESERVOIR. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube, PN 4306968 (Figure 4-B). 4. Install return hose assembly, PN 4418006, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end (Figure 4-B). 5. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 42O3576. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1844 FIGURE 4B - Mounting Fuel Resevoir/Filter 6. Install one 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the fuel pump outlet tube to the reservoir/filter inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). 7. Install the other 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 8. Tighten all hose clamps to 10 inch pounds. FIGURE 10 9. Type Authorized Modification Label, PN 4275086, as shown in Figure 10 and attach near VECI label. 10. For all models except 1981-1984 equipped with Carter Thermoquad 4BBL carburetor or dual air conditioning units without electrically Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1845 heated rear window defroster. Reconnect battery. Start the engine, and inspect the entire system for fuel leaks and proper wire and hose routing. 11. Reinstall engine cover. F.1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (Pn 4397 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6O22254, (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT, AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6O22254. THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1846 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference with nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose-to-regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. For all models except those equipped with dual air conditioning units, without electrically heated rear window defroster and with 60 amp alternator: 6. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 7. Reinstall engine cover. G.Vehicles Equipped With Dual Air Conditioning Units, Without Electrically Heated Rear Defroster, and With 60 Amp Alternator. I Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1847 HEADLAMP AND DASH WIRING ASSEMBLY 1. Disconnect the battery positive lead (single in-line connection) from the headlamp and dash wiring assembly (Figure 6-A). FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 2. Remove the following wires from the engine compartment side of the bulkhead connector (Figure 6-B). a. Red wire from cavity #39 (ammeter). b. Black wire from cavity #33 (ammeter). Cut off the terminals and wrap tape around each end of both wires to insure that shorting cannot occur. Then tape the wrapped wires back against the main harness. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1848 FIGURE 6-C - 78 AMP ALTERNATOR WIRING 3. Remove the alternator output wire (heavy gauge) from the 60 amp alternator (Figure 6-C). Cut the wire off leaving approximately three (3) inches of wire extending out of the main harness. Tape the end of the lead thoroughly. Then fold and tape the lead back against the main harness to prevent shorting. 4. Remove 60 amp alternator assembly and install 78 amp alternator assembly, PN 4111204, per the service manual alternator replacement procedure. HEADLAMP AND DASH WIRING ASSEMBLY Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1849 FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 5. Beginning at the bulkhead, route and connect the wiring assembly, PN 4362343, as shown in Figure 6-A. Use the existing clip for main harness and tie wrap with three (3) tie wraps, PN 6015756. Insert the two bare terminals from alternator overlay wiring harness, PN 4362343, as shown in Figure 6-B as follows: NOTE: THE 4362343 ALTERNATOR OVERLAY HARNESS WAS MANUFACTURED WITH THE RED AND BLACK WIRES REVERSED. THEREFORE, IT WILL BE NECESSARY TO INSTALL THE BLACK WIRE (LABELED RED) INTO CAVITY #39 (RED WIRE PREVIOUSLY REMOVED), AND THE RED WIRE (LABELED BLACK) INTO CAVITY #33 (BLACK WIRE PREVIOUSLY REMOVED). FAILURE TO REVERSE THESE TWO WIRES WILL RESULT IN THE AMMETER SHOWING THE OPPOSITE CHARGE INDICATION. a. Red wire into cavity #33 (ammeter) - (labeled as black wire). b. Black wire into cavity #39 (ammeter) - (labeled as red wire). 6. Install wiring assembly, PN 4362343, alternator output terminal to new 78 amp alternator. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1850 FIGURE 6A1 7. Connect the battery positive lead and the headlamp and dash wiring assembly lead to those of the alternator overlay wiring assembly, PN 4362343, as shown in circled view of Figure 6-A. 8. Reinstall instrument panel half, then engine compartment half of bulkhead connector and torque to 40 inch pounds. 9. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 10. Reinstall engine cover. POLICY: Reimbursable within the provisions of the warranty and repair manual. TIME ALLOWANCE: Labor Operation No. 14-70-17-94 - All 2.5 Hrs. Optional Equipment: 14-70-17-60 - Carter Thermoquad Carburetor 0.5 Hrs. 14-70-17-61 - With Auxiliary A/C - Without Elec. 0.7 Hrs. Rear Window Defroster 14-70-17-62 - Without Auxiliary A/C 0.3 Hrs. 14-70-17-63 - With Auxiliary A/C - Without 0.4 Hrs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1851 Power Windows FAILURE CODE: AM - Authorized Modification Part List VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 22 GALLON FUEL TANK PACKAGE PART NO. 4397611 QTY PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075432 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Seal - Fuel Tank Gauge 3404451 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 36 GALLON FUEL TANK PACKAGE PART NO. 4397612 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075436 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Gasket - Fuel Tank Sending Unit 4115209 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1852 *It may be necessary to order clamp separately on early released packages. PARTS LIST FUEL PRESSURE REGULATOR PACKAGE FOR 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO.4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 PARTS LIST 78 AMP ALTERNATOR PACKAGE FOR 1981-1985 B MODEL TRUCKS WITH 5.2L OR 5.9L ENGINES PACKAGE PART NO. 4397615 QTY. PART NAME PART NO. 1 78 AMP Alternator Assembly - Complete 4111204 1 Alternator Overlay Wiring Harness 4362343 4 Tie Wrap 6015756 1 Gasket - Bulkhead Connector 4055399 FIGURE 4B - Mounting Fuel Resevoir/Filter 1. Fuel Filter/ Reservoir - 4418012 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1853 2. Screw - Self Tapping - 6022777 (2 Req.) 3. Tube Assy - Fuel Pump to Reservoir - 4306968 4. Return Hose & Sleeve Assy - 4418006 5. Hose Clamps - 6500650 (2 Req.) - 1/4" 6. Hose-Fuel Pump Outlet to Reservoir Inlet - 4203576 7. Hose-Reservoir Outlet to Carburetor or Regulator Fuel Tube - 4203576 8. Hose Clamps - 6500651 (4 Req.) - 5/16" Included but not shown: 2 piece Convolute Tubing - 4279993 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1 SCREW & WASHER - 6022254 2 REGULATOR BRACKET - 4418010 3 REGULATOR - 4418OD9 4 TUBE - REGULATOR TO CARB - 4418008 5 TUBE - RESERVOIR HOSE TO REGULATOR - 4418014 6 SCREW (2 EA.) - REGULATOR TO BRACKET - 6033066 7 CLAMP (5116) - 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 182985 > Jun > 85 > ECM - Warm Surge At Steady Speed Powertrain Control Module: Customer Interest ECM - Warm Surge At Steady Speed Models 1985 Trucks Equipped With 5.2L-2BBL Engine, O2 Feedback Carburetor System & Automatic Transmission With California Emissions Package Subject Warm Surge at Steady Speed Index DRIVEABILITY Date June 24, 1985 No.. 18-29-85 SYMPTOM/CONDITION Vehicle will exhibit a surge at steady speeds with engine at full operating temperature. PARTS REQUIRED Driveability Package PN 4397618 Contains: 1 Vacuum Delay Valve PN 4173433 1 Hose Routing Label PN 4179843 Must be ordered separately: 1 ESA Module PN 4289977 1 CVSCC PN 4095231 1 Authorized Modification Label PN 4275086 REPAIR PROCEDURE 1. Remove existing ESA module (PN 4289637) and install supplied ESA module, PN 4289977. 2. Drain coolant and remove existing CVSCC (coolant vacuum switch cold closed) and install supplied CVSCC, PN 4095231. 3. Cut one 1-1/2" section of 3/16" vacuum hose, PN 4105167 (serviced in 50 foot rolls). 4. Install the 1-1/2" section of 3/16" hose on the natural colored end of the vacuum delay valve, PN 4173433, supplied in package. 5. The EGR solenoid is mounted on the fender shield (right side of engine compartment). It can be identified by a "white" right angle vacuum connector. Remove the white right angle vacuum connector on the EGR solenoid and install the delay valve assembly on the EGR solenoid. The 1-1/2" piece of 3/16" hose is attached in place of the removed white right angle connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 182985 > Jun > 85 > ECM - Warm Surge At Steady Speed > Page 1858 FIGURE 1 - Vacuum Delay Valve - Attachment Procedure The white right angle connector is then attached to the orange colored side of the vacuum delay valve (Figure 1). 6. Wipe existing hose routing label clean. Install hose routing label, PN 4179843, supplied in package over the original label. FIGURE 2 7. Type Authorized Modification Label, PN 4275086, as shown in Figure 2 and install next to the VECI label. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 08-15-61-90 Trucks 0.5 Hrs. Vans 0.6 Hrs. FAILURE CODE: AM - Authorized Modification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1864 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1865 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1866 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1867 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1868 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1869 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1870 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1871 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1872 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1873 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1874 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1875 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1876 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1877 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 1878 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock Technical Service Bulletin # 181985A Date: 851201 Fuel System - Vapor Lock Models 1981-1985 Van & Wagon Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 20, 1985 No. 18-19-85 REVISION A P-4782-C This bulletin supersedes Technical Service Bulletin #18-19-85 which should be removed from your files. The model application has been expanded to include 1981 and 1982 model years. SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING TWO PART NUMBERS: Vapor Lock Package With 22 Gallon Fuel Tank PN 4397611 Vapor Lock Package With 36 Gallon Fuel Tank PN 4397612 ADDITIONAL PARTS INFORMATION ON NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 All vehicles equipped with dual air conditioning, without electrically heated rear window defroster, and with 60 amp alternator must order the following package in addition to the vapor lock package. If vehicle is equipped with a 114 amp alternator, do not order this package or make any changes to the charging system. 1 78 AMP Alternator Package PN 4397615 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1883 Refer to parts list for contents of each package. Must be ordered separately: 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. REPAIR PROCEDURE A.Engine Compartment Harness Pn 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1A - ENGINE COMPARTMENT WIRING 3. Remove engine cover. Install the bare eyelet terminal of overlay harness, PN 4362295, to the negative terminal of the ignition coil as shown in Figure 1-A. FIGURE 1B - ENGINE COMPARTMENT WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1884 4. Route and secure the engine overlay harness, PN 4362295, along the existing main engine wiring harness using the existing wiring clips and two tie wraps, PN 6015756 (Figure 1-B). FIGURE 1C - ENGINE COMPARTMENT WIRING 5. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness to the bulkhead connector using the existing wiring clips and three tie wraps, PN 6015756 (Figure 1-C). Loop and tape any excess wire of the engine overlay harness. FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 6. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar multi-purpose grease PN 4318063, and snap into cavity #14 of the engine side of the bulkhead connector (Figure 1-D). B.Instrument Panel Harnesses Pn 4362289, All Models Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1885 FIGURE 2A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) 1. Remove instrument panel left lower trim panel. 2. Insert two bare terminals from instrument panel overlay harness, PN 4362289, into the instrument panel side of the bulkhead connector (Figure 2-A). a. Gray with black tracer wire into cavity #14. b. Dark green wire into cavity #13. INSTRUMENT PANEL WIRING 3. Secure bare eyelet ground terminal (white with black tracer wire) from instrument panel overlay harness, PN 4362289, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). NOTE: CERTAIN VEHICLES ARE ALREADY EQUIPPED WITH THE GROUND SCREW. IF SO, DISCARD THE SUPPLIED SCREW. FIGURE 2C - INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1886 FIGURE 2D - INSTRUMENT PANEL WIRING 4. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-C). Install the extracted terminal (orange wire) into the natural colored 1-way connector supplied with instrument panel overlay harness, PN 4362289. Install the bare terminal (orange wire) from the instrument panel overlay harness, PN 4362289, into the vacated cavity in the ignition switch connector. Reconnect the natural colored 1-way connectors supplied with the instrument panel overlay harness, PN 4362289, and reconnect the ignition switch connectors (Figure 2-C and 2-D). FIGURE 2E - TYPICAL CONTROL MODULE MOUNTING 5. Connect the control (auto shut-down) module, PN 5226640, to the natural colored 8-way connector from instrument panel overlay harness, PN 4362289. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1887 FIGURE 2D - INSTRUMENT PANEL WIRING FIGURE 2F - INSTRUMENT PANEL WIRING 6. Route the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289, to the back of the brake bracket for mating in a later step (Figures 2-B, 2-D, and 2-F). Secure instrument panel overlay harness, PN 4362289, using tie wrap, PN 6015756, to keep it clear of any possible interferences. Only one of the following installation procedures (Step 7) will be used. Take notice of which one applies to the vehicle being repaired. 7. Without Auxiliary Air Conditioning and/or Heater - Jumper Harness PN 4362291 a. Remove instrument panel hood and bezel assembly and remove radio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1888 FIGURE 2D - INSTRUMENT PANEL WIRING b. Route instrument panel jumper harness, PN 4362291, from the back of the brake bracket to the existing 3-way red molded connector. Secure by using existing wiring clips (Figure 2-D). c. Insert the bare bullet terminal (black with white tracer wire) from instrument panel jumper harness, PN 4362291, into the existing 3-way red molded connector from the main instrument panel wiring harness (Figure 2-D). d. Mate the orange colored 1-way connector from instrument panel jumper harness, PN 4362291, to the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). e. Reinstall instrument panel hood and bezel assembly and install radio. FIGURE 2F - INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater and Power Windows - Jumper Harness PN 4362292 a. Disconnect from each other, the two existing brown colored 1-way connectors located near the left instrument panel vent (Figure 2-F). Reconnect these two brown colored 1-way connectors to the two brown colored 1-way connectors from instrument panel jumper harness, PN 4362292 (Figure 2-F). b. Mate the orange colored 1-way connector from the instrument panel jumper harness, PN 4362292, to the orange colored 1-way connector from instrument panel overlay harness, PN 4362289 (Figure 2-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1889 INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater Without Power Windows - Relay Harness PN 4362290 a. Remove instrument panel hood and bezel assembly. Remove radio. b. Install the ignition switch protection relay, PN 4162597, to the back of the brake bracket (mounting location shown in Figure 2-B) and attach instrument panel relay harness, PN 4362290, to relay. c. Secure bare eyelet ground terminal (white wire) from instrument panel relay harness, PN 4362290, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING d. Route the dark blue wire from the instrument panel relay harness, PN 4362290 to the existing 3-way red molded connector using existing wiring clips. Insert bullet terminal (dark blue wire) into red molded connector (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1890 INSTRUMENT PANEL WIRING e. Insert bare bullet terminal (red wire) from instrument panel relay harness, PN 4362290, into the existing 3-way yellow molded connector from the main instrument panel wiring harness (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING f. Mate the orange colored 1-way connector from instrument panel relay harness, PN 4362290, to the colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). g. Install the instrument panel left lower trim panel, instrument panel hood, bezel assembly and radio. C.In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Feed red and yellow molds of body wiring harness, PN 4362293, through slot in the crossmember. Remove existing screw for gauge unit ground. Install eyelet terminal of harness, PN 4362293 (and ground eyelet terminal of 36 gallon tank gauge/pump unit) and torque ground screw to 36 inch pounds. CAUTION: GROUND SCREW MUST BE TIGHTENED SECURELY TO OPERATE ELECTRIC PUMP AND GAUGE UNIT. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1891 FIGURE 3A - BODY WIRING FIGURE 3B - BODY WIRING Install red mold of body harness, PN 4362293, onto red stud of gauge/pump unit. Install yellow mold of harness, PN 4362293, onto black stud of gauge/pump unit (figure 3-a or 3-b). Install molded blade terminal of harness, PN 4362293, onto blade terminal of 22 gallon gauge unit only. NOTE: PREVIOUS GAUGE UNIT GROUND WILL NOT BE USED ON 22 GALLON GAUGE/PUMP UNIT. ON 36 GALLON GAUGE PUMP UNIT, THE GROUND WIRE ON HARNESS PN 4362293 WILL NOT BE USED. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. Set aside the rest of harness, PN 4362293, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. D.Body Wiring Harness Pn 4362293 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1892 FIGURE 3C - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1893 FIGURE 3-F - BODY WIRING 1. Vehicles With 36 Gallon Tank Route harness, PN 4362293, to the right (passenger) side of vehicle along the fuel line tubes and tie wrap (1). At right frame rail, route harness forward to next crossmember (Figures 3-C and 3-E). Tie wrap harness in three (3) places. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1894 FIGURE 3D - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1895 FIGURE 3-F - BODY WIRING Vehicles With 22 Gallon Tank Route harness, PN 4362293, along right frame rail following brake lines (Figures 3-D and 3-E). Tie wrap in two (2) places. NOTE: HARNESS MUST BE ABOVE SHOCK STRUT WITH EITHER 36 OR 22 GALLON TANK. 2. At crossmember, route harness to the left rail following existing brake lines and tie wrap in two (2) places. At left rail, route harness forward through access holes following existing brake lines. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1896 FIGURE 3-F - BODY WIRING NOTE: HARNESS SHOULD BE TIGHT IN THIS AREA THE WRAP IN FOUR (4) PLACES (FIGURE 3-E). 3. At engine compartment, route harness through existing speedometer cable clips to bulkhead connector. If excess wiring exists; loop, tie wrap (2), and install into existing clip (Figure 3-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1897 FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 4. Plug bare terminal of harness, PN 4362293, into cavity #13 of the bulkhead connector (Figure 1-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1898 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1899 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1900 FIGURE 9 - ELECTRIC FUEL PUMP WIRING DIAGRAMW/AUX A/C & HEATER-W/O POWER WINDOWS 5. For all vehicles except those which require a 78 amp alternator package: Reinstall instrument panel side, then engine compartment side of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURES 7, 8, OR 9 FOR OVERALL WIRING DIAGRAMS. E.Engine Compartment Fuel Reservoir/Filter Lnstallation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1901 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER 1. Using template, PN 4418011, mark and drill (from engine side of passenger side chassis rail) two (2) holes .290" diameter (L size drill) as shown in Figure 4-A. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1902 FIGURE 4B - Mounting Fuel Resevoir/Filter 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. NOTE: RUBBER SPLASH SHIELD MAY HAVE TO BE CUT OUT AROUND FUEL RESERVOIR. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube, PN 4306968 (Figure 4-B). 4. Install return hose assembly, PN 4418006, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end (Figure 4-B). 5. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 42O3576. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1903 FIGURE 4B - Mounting Fuel Resevoir/Filter 6. Install one 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the fuel pump outlet tube to the reservoir/filter inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). 7. Install the other 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 8. Tighten all hose clamps to 10 inch pounds. FIGURE 10 9. Type Authorized Modification Label, PN 4275086, as shown in Figure 10 and attach near VECI label. 10. For all models except 1981-1984 equipped with Carter Thermoquad 4BBL carburetor or dual air conditioning units without electrically Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1904 heated rear window defroster. Reconnect battery. Start the engine, and inspect the entire system for fuel leaks and proper wire and hose routing. 11. Reinstall engine cover. F.1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (Pn 4397 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6O22254, (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT, AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6O22254. THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1905 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference with nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose-to-regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. For all models except those equipped with dual air conditioning units, without electrically heated rear window defroster and with 60 amp alternator: 6. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 7. Reinstall engine cover. G.Vehicles Equipped With Dual Air Conditioning Units, Without Electrically Heated Rear Defroster, and With 60 Amp Alternator. I Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1906 HEADLAMP AND DASH WIRING ASSEMBLY 1. Disconnect the battery positive lead (single in-line connection) from the headlamp and dash wiring assembly (Figure 6-A). FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 2. Remove the following wires from the engine compartment side of the bulkhead connector (Figure 6-B). a. Red wire from cavity #39 (ammeter). b. Black wire from cavity #33 (ammeter). Cut off the terminals and wrap tape around each end of both wires to insure that shorting cannot occur. Then tape the wrapped wires back against the main harness. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1907 FIGURE 6-C - 78 AMP ALTERNATOR WIRING 3. Remove the alternator output wire (heavy gauge) from the 60 amp alternator (Figure 6-C). Cut the wire off leaving approximately three (3) inches of wire extending out of the main harness. Tape the end of the lead thoroughly. Then fold and tape the lead back against the main harness to prevent shorting. 4. Remove 60 amp alternator assembly and install 78 amp alternator assembly, PN 4111204, per the service manual alternator replacement procedure. HEADLAMP AND DASH WIRING ASSEMBLY Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1908 FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 5. Beginning at the bulkhead, route and connect the wiring assembly, PN 4362343, as shown in Figure 6-A. Use the existing clip for main harness and tie wrap with three (3) tie wraps, PN 6015756. Insert the two bare terminals from alternator overlay wiring harness, PN 4362343, as shown in Figure 6-B as follows: NOTE: THE 4362343 ALTERNATOR OVERLAY HARNESS WAS MANUFACTURED WITH THE RED AND BLACK WIRES REVERSED. THEREFORE, IT WILL BE NECESSARY TO INSTALL THE BLACK WIRE (LABELED RED) INTO CAVITY #39 (RED WIRE PREVIOUSLY REMOVED), AND THE RED WIRE (LABELED BLACK) INTO CAVITY #33 (BLACK WIRE PREVIOUSLY REMOVED). FAILURE TO REVERSE THESE TWO WIRES WILL RESULT IN THE AMMETER SHOWING THE OPPOSITE CHARGE INDICATION. a. Red wire into cavity #33 (ammeter) - (labeled as black wire). b. Black wire into cavity #39 (ammeter) - (labeled as red wire). 6. Install wiring assembly, PN 4362343, alternator output terminal to new 78 amp alternator. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1909 FIGURE 6A1 7. Connect the battery positive lead and the headlamp and dash wiring assembly lead to those of the alternator overlay wiring assembly, PN 4362343, as shown in circled view of Figure 6-A. 8. Reinstall instrument panel half, then engine compartment half of bulkhead connector and torque to 40 inch pounds. 9. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 10. Reinstall engine cover. POLICY: Reimbursable within the provisions of the warranty and repair manual. TIME ALLOWANCE: Labor Operation No. 14-70-17-94 - All 2.5 Hrs. Optional Equipment: 14-70-17-60 - Carter Thermoquad Carburetor 0.5 Hrs. 14-70-17-61 - With Auxiliary A/C - Without Elec. 0.7 Hrs. Rear Window Defroster 14-70-17-62 - Without Auxiliary A/C 0.3 Hrs. 14-70-17-63 - With Auxiliary A/C - Without 0.4 Hrs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1910 Power Windows FAILURE CODE: AM - Authorized Modification Part List VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 22 GALLON FUEL TANK PACKAGE PART NO. 4397611 QTY PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075432 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Seal - Fuel Tank Gauge 3404451 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 36 GALLON FUEL TANK PACKAGE PART NO. 4397612 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075436 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Gasket - Fuel Tank Sending Unit 4115209 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1911 *It may be necessary to order clamp separately on early released packages. PARTS LIST FUEL PRESSURE REGULATOR PACKAGE FOR 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO.4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 PARTS LIST 78 AMP ALTERNATOR PACKAGE FOR 1981-1985 B MODEL TRUCKS WITH 5.2L OR 5.9L ENGINES PACKAGE PART NO. 4397615 QTY. PART NAME PART NO. 1 78 AMP Alternator Assembly - Complete 4111204 1 Alternator Overlay Wiring Harness 4362343 4 Tie Wrap 6015756 1 Gasket - Bulkhead Connector 4055399 FIGURE 4B - Mounting Fuel Resevoir/Filter 1. Fuel Filter/ Reservoir - 4418012 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 1912 2. Screw - Self Tapping - 6022777 (2 Req.) 3. Tube Assy - Fuel Pump to Reservoir - 4306968 4. Return Hose & Sleeve Assy - 4418006 5. Hose Clamps - 6500650 (2 Req.) - 1/4" 6. Hose-Fuel Pump Outlet to Reservoir Inlet - 4203576 7. Hose-Reservoir Outlet to Carburetor or Regulator Fuel Tube - 4203576 8. Hose Clamps - 6500651 (4 Req.) - 5/16" Included but not shown: 2 piece Convolute Tubing - 4279993 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1 SCREW & WASHER - 6022254 2 REGULATOR BRACKET - 4418010 3 REGULATOR - 4418OD9 4 TUBE - REGULATOR TO CARB - 4418008 5 TUBE - RESERVOIR HOSE TO REGULATOR - 4418014 6 SCREW (2 EA.) - REGULATOR TO BRACKET - 6033066 7 CLAMP (5116) - 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 182985 > Jun > 85 > ECM - Warm Surge At Steady Speed Powertrain Control Module: All Technical Service Bulletins ECM - Warm Surge At Steady Speed Models 1985 Trucks Equipped With 5.2L-2BBL Engine, O2 Feedback Carburetor System & Automatic Transmission With California Emissions Package Subject Warm Surge at Steady Speed Index DRIVEABILITY Date June 24, 1985 No.. 18-29-85 SYMPTOM/CONDITION Vehicle will exhibit a surge at steady speeds with engine at full operating temperature. PARTS REQUIRED Driveability Package PN 4397618 Contains: 1 Vacuum Delay Valve PN 4173433 1 Hose Routing Label PN 4179843 Must be ordered separately: 1 ESA Module PN 4289977 1 CVSCC PN 4095231 1 Authorized Modification Label PN 4275086 REPAIR PROCEDURE 1. Remove existing ESA module (PN 4289637) and install supplied ESA module, PN 4289977. 2. Drain coolant and remove existing CVSCC (coolant vacuum switch cold closed) and install supplied CVSCC, PN 4095231. 3. Cut one 1-1/2" section of 3/16" vacuum hose, PN 4105167 (serviced in 50 foot rolls). 4. Install the 1-1/2" section of 3/16" hose on the natural colored end of the vacuum delay valve, PN 4173433, supplied in package. 5. The EGR solenoid is mounted on the fender shield (right side of engine compartment). It can be identified by a "white" right angle vacuum connector. Remove the white right angle vacuum connector on the EGR solenoid and install the delay valve assembly on the EGR solenoid. The 1-1/2" piece of 3/16" hose is attached in place of the removed white right angle connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 182985 > Jun > 85 > ECM - Warm Surge At Steady Speed > Page 1917 FIGURE 1 - Vacuum Delay Valve - Attachment Procedure The white right angle connector is then attached to the orange colored side of the vacuum delay valve (Figure 1). 6. Wipe existing hose routing label clean. Install hose routing label, PN 4179843, supplied in package over the original label. FIGURE 2 7. Type Authorized Modification Label, PN 4275086, as shown in Figure 2 and install next to the VECI label. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 08-15-61-90 Trucks 0.5 Hrs. Vans 0.6 Hrs. FAILURE CODE: AM - Authorized Modification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations Powertrain Control Module: Component Locations Electronic Ignition System Components On Firewall Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 1920 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 1923 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Feedback Control Solenoid > Component Information > Locations > Component Locations Feedback Control Solenoid: Component Locations Engine Mounted Switches & Sensors. On Carburetor Applicable to: V8 Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Feedback Control Solenoid > Component Information > Locations > Component Locations > Page 1928 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Feedback Control Solenoid > Component Information > Locations > Page 1929 Feedback Control Solenoid: Description and Operation Since this system requires more precise fuel metering for efficient operation then is possible with a conventional carburetor, Electronic Feedback Carburetors, Holley model 6520 is used on four cylinder engines, 6280 on V6 and V8 engines, 6145 on Inline-6 cylinder, and the Carter BBD carburetor on V8 engines are used. The feedback solenoid provides limited regulation of the air-fuel ratio on a feedback carburetor in response to electrical signals from the Spark Control Computer. It performs this task by metering air flow and operating in parallel with a conventional fixed main metering jet. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 1933 Idle Speed/Throttle Actuator - Electronic: Locations Engine Mounted Switches & Sensors. On Carburetor Applicable to: V8 Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 1934 Idle Speed/Throttle Actuator - Electronic: Description and Operation Fig. 46 Vacuum throttle positioner system Some vehicles are equipped with a throttle positioner system to prevent unburned hydrocarbon emissions through the exhaust system when the engine is decelerated from a high RPM. This system consists of an electronic speed switch, an electrically controlled vacuum solenoid valve and a vacuum actuated throttle positioner, Fig. 46. The electronic speed switch senses ignition pulses from the 5 ohm ballast resistor terminal connected to the ignition control unit. When engine speed exceeds 2000 RPM, the speed switch allows vacuum to energize the throttle positioner. When the positioner is energized, a throttle stop provided, will prevent the engine from returning to the idle position. When the throttle is released, it will return the idle to 1750 RPM. As the engine decelerates, the electronic speed switch senses when the engine speed drops below 2000 RPM and de-energizes the throttle positioner. This permits the throttle to return to the normal idle stop position and the engine will continue to decelerate to the idle speed. This operation positions the throttle partially open (1750 RPM) whenever the engine decelerates from a speed above 2000 RPM to a speed just below 2000 RPM, thus providing sufficient air flow through the engine to dilute the air/fuel mixture. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Up Control Valve > Component Information > Adjustments Idle Up Control Valve: Adjustments VACUUM THROTTLE POSITIONER, ADJUST 1. Start engine and allow to idle in neutral, then accelerate engine to above 2000 RPM to make sure that throttle positioner operates and can maintain its position when a hand load is applied. If not, determine cause of malfunction and correct as necessary as described under ``Testing'' procedure before proceeding further. 2. Accelerate engine to about 2500 RPM then loosen positioner adjustment lock nut and rotate positioner assembly until it just contacts throttle lever. 3. Release throttle and adjust positioner to decrease engine speed until a sudden drop in speed occurs (over 1000 RPM). Continue adjusting positioner in decreasing direction 1/4 turn and tighten lock nut. 4. Accelerate engine to about 2500 RPM and release throttle. If engine speed returns to normal idle, throttle positioner is properly adjusted. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Component Locations Detonation (Knock) Sensor: Component Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Component Locations > Page 1942 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Page 1943 Detonation (Knock) Sensor: Description and Operation Fig. 12 Detonation sensor location. V8 engine The detonation sensor, Fig. 12, is used on V8 engines only and is located in the intake manifold. It signals the computer when detonation occurs so that the ignition timing can be retarded. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications All models with TBI. Apply 5" (125mm) Hg to unit and record output voltage. Apply 20" (500mm) Hg to unit, the difference in voltage should be 2.3 - 2.9. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1947 Manifold Pressure/Vacuum Sensor: Locations Combustion Control Computer Location. Upper RH Side Of Engine Applicable to: 1981-84 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1948 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 7 Spark control computer & vacuum transducer location. V8 engine The vacuum transducer is located on the computer and it provides the computer with information on engine vacuum, Fig. 7. It is used to control spark advance and air fuel ratios. And indicates engine load. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Mixture Control Solenoid > Component Information > Locations Mixture Control Solenoid: Locations Engine Mounted Switches & Sensors. On Carburetor Applicable to: V8 Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Engine Mounted Switches & Sensors. Lower RH Side Of Engine Applicable to: V8 Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1957 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1958 Oxygen Sensor: Description and Operation Fig. 7 Spark control computer & vacuum transducer location. V8 engine To provide the EFC system with an indication of the exhaust gas composition, an oxygen sensor is threaded into the exhaust manifold and is exposed directly to exhaust gas stream, Fig. 7. The sensor is sensitive to the presence of or lack of oxygen. With an oxygen deficiency in the exhaust gas, outside oxygen diffuses through the sensor, acting as an electrolyte and generating a voltage. The oxygen sensor is basically a galvanic battery consisting of a cylindrical electrolyte element of zirconium dioxide which is coated inside and out with platinum. The outer platinum electrode is exposed to atmosphere, while the inner is exposed to the hot exhaust gases. A porous ceramic (spinel) coating protects the platinum against damage. When heated to operating temperature by the hot exhaust gases, the sensor generates a voltage. If the oxygen is high, a low voltage (below .45 volts) will be produced. When the oxygen content is low (rich mixture), a high voltage (.45 to 1 volt) will be produced. This relationship between available oxygen and sensor output voltage causes the sensor to function as a rich-lean switch. The sensor output voltage is used by the Feedback Carburetor Controller to calculate and adjust the air-fuel mixture as needed for optimum catalytic converter operation. The sensor's internal impedance, output voltage and time response are all functions of temperature. This temperature dependency is important during cold starts and other low temperature operating modes. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1964 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Power Module <--> [Electronic Spark Control Module] > Component Information > Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Power Module <--> [Electronic Spark Control Module] > Component Information > Locations > Page 1968 Power Module: Description and Operation The spark control computer controls the air fuel ratio of the carburetor and the ignition timing. The computer receives signals from various sensors and processes them to determine the air fuel ratio of the carburetor and ignition timing. There are as many as six types of sensors which can be used to supply the spark control computer with the necessary information needed to fire the spark plugs at the precise moment and, with the feedback carburetor, change the air-fuel ratio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 1977 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 1978 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 1979 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 1980 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 1981 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 1982 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 1983 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 1984 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 1985 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 1986 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 1987 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 1988 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 1989 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 1990 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 1991 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock Technical Service Bulletin # 181985A Date: 851201 Fuel System - Vapor Lock Models 1981-1985 Van & Wagon Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 20, 1985 No. 18-19-85 REVISION A P-4782-C This bulletin supersedes Technical Service Bulletin #18-19-85 which should be removed from your files. The model application has been expanded to include 1981 and 1982 model years. SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING TWO PART NUMBERS: Vapor Lock Package With 22 Gallon Fuel Tank PN 4397611 Vapor Lock Package With 36 Gallon Fuel Tank PN 4397612 ADDITIONAL PARTS INFORMATION ON NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 All vehicles equipped with dual air conditioning, without electrically heated rear window defroster, and with 60 amp alternator must order the following package in addition to the vapor lock package. If vehicle is equipped with a 114 amp alternator, do not order this package or make any changes to the charging system. 1 78 AMP Alternator Package PN 4397615 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 1996 Refer to parts list for contents of each package. Must be ordered separately: 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. REPAIR PROCEDURE A.Engine Compartment Harness Pn 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1A - ENGINE COMPARTMENT WIRING 3. Remove engine cover. Install the bare eyelet terminal of overlay harness, PN 4362295, to the negative terminal of the ignition coil as shown in Figure 1-A. FIGURE 1B - ENGINE COMPARTMENT WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 1997 4. Route and secure the engine overlay harness, PN 4362295, along the existing main engine wiring harness using the existing wiring clips and two tie wraps, PN 6015756 (Figure 1-B). FIGURE 1C - ENGINE COMPARTMENT WIRING 5. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness to the bulkhead connector using the existing wiring clips and three tie wraps, PN 6015756 (Figure 1-C). Loop and tape any excess wire of the engine overlay harness. FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 6. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar multi-purpose grease PN 4318063, and snap into cavity #14 of the engine side of the bulkhead connector (Figure 1-D). B.Instrument Panel Harnesses Pn 4362289, All Models Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 1998 FIGURE 2A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) 1. Remove instrument panel left lower trim panel. 2. Insert two bare terminals from instrument panel overlay harness, PN 4362289, into the instrument panel side of the bulkhead connector (Figure 2-A). a. Gray with black tracer wire into cavity #14. b. Dark green wire into cavity #13. INSTRUMENT PANEL WIRING 3. Secure bare eyelet ground terminal (white with black tracer wire) from instrument panel overlay harness, PN 4362289, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). NOTE: CERTAIN VEHICLES ARE ALREADY EQUIPPED WITH THE GROUND SCREW. IF SO, DISCARD THE SUPPLIED SCREW. FIGURE 2C - INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 1999 FIGURE 2D - INSTRUMENT PANEL WIRING 4. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-C). Install the extracted terminal (orange wire) into the natural colored 1-way connector supplied with instrument panel overlay harness, PN 4362289. Install the bare terminal (orange wire) from the instrument panel overlay harness, PN 4362289, into the vacated cavity in the ignition switch connector. Reconnect the natural colored 1-way connectors supplied with the instrument panel overlay harness, PN 4362289, and reconnect the ignition switch connectors (Figure 2-C and 2-D). FIGURE 2E - TYPICAL CONTROL MODULE MOUNTING 5. Connect the control (auto shut-down) module, PN 5226640, to the natural colored 8-way connector from instrument panel overlay harness, PN 4362289. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2000 FIGURE 2D - INSTRUMENT PANEL WIRING FIGURE 2F - INSTRUMENT PANEL WIRING 6. Route the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289, to the back of the brake bracket for mating in a later step (Figures 2-B, 2-D, and 2-F). Secure instrument panel overlay harness, PN 4362289, using tie wrap, PN 6015756, to keep it clear of any possible interferences. Only one of the following installation procedures (Step 7) will be used. Take notice of which one applies to the vehicle being repaired. 7. Without Auxiliary Air Conditioning and/or Heater - Jumper Harness PN 4362291 a. Remove instrument panel hood and bezel assembly and remove radio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2001 FIGURE 2D - INSTRUMENT PANEL WIRING b. Route instrument panel jumper harness, PN 4362291, from the back of the brake bracket to the existing 3-way red molded connector. Secure by using existing wiring clips (Figure 2-D). c. Insert the bare bullet terminal (black with white tracer wire) from instrument panel jumper harness, PN 4362291, into the existing 3-way red molded connector from the main instrument panel wiring harness (Figure 2-D). d. Mate the orange colored 1-way connector from instrument panel jumper harness, PN 4362291, to the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). e. Reinstall instrument panel hood and bezel assembly and install radio. FIGURE 2F - INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater and Power Windows - Jumper Harness PN 4362292 a. Disconnect from each other, the two existing brown colored 1-way connectors located near the left instrument panel vent (Figure 2-F). Reconnect these two brown colored 1-way connectors to the two brown colored 1-way connectors from instrument panel jumper harness, PN 4362292 (Figure 2-F). b. Mate the orange colored 1-way connector from the instrument panel jumper harness, PN 4362292, to the orange colored 1-way connector from instrument panel overlay harness, PN 4362289 (Figure 2-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2002 INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater Without Power Windows - Relay Harness PN 4362290 a. Remove instrument panel hood and bezel assembly. Remove radio. b. Install the ignition switch protection relay, PN 4162597, to the back of the brake bracket (mounting location shown in Figure 2-B) and attach instrument panel relay harness, PN 4362290, to relay. c. Secure bare eyelet ground terminal (white wire) from instrument panel relay harness, PN 4362290, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING d. Route the dark blue wire from the instrument panel relay harness, PN 4362290 to the existing 3-way red molded connector using existing wiring clips. Insert bullet terminal (dark blue wire) into red molded connector (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2003 INSTRUMENT PANEL WIRING e. Insert bare bullet terminal (red wire) from instrument panel relay harness, PN 4362290, into the existing 3-way yellow molded connector from the main instrument panel wiring harness (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING f. Mate the orange colored 1-way connector from instrument panel relay harness, PN 4362290, to the colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). g. Install the instrument panel left lower trim panel, instrument panel hood, bezel assembly and radio. C.In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Feed red and yellow molds of body wiring harness, PN 4362293, through slot in the crossmember. Remove existing screw for gauge unit ground. Install eyelet terminal of harness, PN 4362293 (and ground eyelet terminal of 36 gallon tank gauge/pump unit) and torque ground screw to 36 inch pounds. CAUTION: GROUND SCREW MUST BE TIGHTENED SECURELY TO OPERATE ELECTRIC PUMP AND GAUGE UNIT. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2004 FIGURE 3A - BODY WIRING FIGURE 3B - BODY WIRING Install red mold of body harness, PN 4362293, onto red stud of gauge/pump unit. Install yellow mold of harness, PN 4362293, onto black stud of gauge/pump unit (figure 3-a or 3-b). Install molded blade terminal of harness, PN 4362293, onto blade terminal of 22 gallon gauge unit only. NOTE: PREVIOUS GAUGE UNIT GROUND WILL NOT BE USED ON 22 GALLON GAUGE/PUMP UNIT. ON 36 GALLON GAUGE PUMP UNIT, THE GROUND WIRE ON HARNESS PN 4362293 WILL NOT BE USED. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. Set aside the rest of harness, PN 4362293, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. D.Body Wiring Harness Pn 4362293 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2005 FIGURE 3C - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2006 FIGURE 3-F - BODY WIRING 1. Vehicles With 36 Gallon Tank Route harness, PN 4362293, to the right (passenger) side of vehicle along the fuel line tubes and tie wrap (1). At right frame rail, route harness forward to next crossmember (Figures 3-C and 3-E). Tie wrap harness in three (3) places. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2007 FIGURE 3D - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2008 FIGURE 3-F - BODY WIRING Vehicles With 22 Gallon Tank Route harness, PN 4362293, along right frame rail following brake lines (Figures 3-D and 3-E). Tie wrap in two (2) places. NOTE: HARNESS MUST BE ABOVE SHOCK STRUT WITH EITHER 36 OR 22 GALLON TANK. 2. At crossmember, route harness to the left rail following existing brake lines and tie wrap in two (2) places. At left rail, route harness forward through access holes following existing brake lines. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2009 FIGURE 3-F - BODY WIRING NOTE: HARNESS SHOULD BE TIGHT IN THIS AREA THE WRAP IN FOUR (4) PLACES (FIGURE 3-E). 3. At engine compartment, route harness through existing speedometer cable clips to bulkhead connector. If excess wiring exists; loop, tie wrap (2), and install into existing clip (Figure 3-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2010 FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 4. Plug bare terminal of harness, PN 4362293, into cavity #13 of the bulkhead connector (Figure 1-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2011 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2012 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2013 FIGURE 9 - ELECTRIC FUEL PUMP WIRING DIAGRAMW/AUX A/C & HEATER-W/O POWER WINDOWS 5. For all vehicles except those which require a 78 amp alternator package: Reinstall instrument panel side, then engine compartment side of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURES 7, 8, OR 9 FOR OVERALL WIRING DIAGRAMS. E.Engine Compartment Fuel Reservoir/Filter Lnstallation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2014 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER 1. Using template, PN 4418011, mark and drill (from engine side of passenger side chassis rail) two (2) holes .290" diameter (L size drill) as shown in Figure 4-A. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2015 FIGURE 4B - Mounting Fuel Resevoir/Filter 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. NOTE: RUBBER SPLASH SHIELD MAY HAVE TO BE CUT OUT AROUND FUEL RESERVOIR. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube, PN 4306968 (Figure 4-B). 4. Install return hose assembly, PN 4418006, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end (Figure 4-B). 5. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 42O3576. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2016 FIGURE 4B - Mounting Fuel Resevoir/Filter 6. Install one 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the fuel pump outlet tube to the reservoir/filter inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). 7. Install the other 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 8. Tighten all hose clamps to 10 inch pounds. FIGURE 10 9. Type Authorized Modification Label, PN 4275086, as shown in Figure 10 and attach near VECI label. 10. For all models except 1981-1984 equipped with Carter Thermoquad 4BBL carburetor or dual air conditioning units without electrically Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2017 heated rear window defroster. Reconnect battery. Start the engine, and inspect the entire system for fuel leaks and proper wire and hose routing. 11. Reinstall engine cover. F.1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (Pn 4397 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6O22254, (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT, AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6O22254. THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2018 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference with nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose-to-regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. For all models except those equipped with dual air conditioning units, without electrically heated rear window defroster and with 60 amp alternator: 6. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 7. Reinstall engine cover. G.Vehicles Equipped With Dual Air Conditioning Units, Without Electrically Heated Rear Defroster, and With 60 Amp Alternator. I Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2019 HEADLAMP AND DASH WIRING ASSEMBLY 1. Disconnect the battery positive lead (single in-line connection) from the headlamp and dash wiring assembly (Figure 6-A). FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 2. Remove the following wires from the engine compartment side of the bulkhead connector (Figure 6-B). a. Red wire from cavity #39 (ammeter). b. Black wire from cavity #33 (ammeter). Cut off the terminals and wrap tape around each end of both wires to insure that shorting cannot occur. Then tape the wrapped wires back against the main harness. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2020 FIGURE 6-C - 78 AMP ALTERNATOR WIRING 3. Remove the alternator output wire (heavy gauge) from the 60 amp alternator (Figure 6-C). Cut the wire off leaving approximately three (3) inches of wire extending out of the main harness. Tape the end of the lead thoroughly. Then fold and tape the lead back against the main harness to prevent shorting. 4. Remove 60 amp alternator assembly and install 78 amp alternator assembly, PN 4111204, per the service manual alternator replacement procedure. HEADLAMP AND DASH WIRING ASSEMBLY Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2021 FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 5. Beginning at the bulkhead, route and connect the wiring assembly, PN 4362343, as shown in Figure 6-A. Use the existing clip for main harness and tie wrap with three (3) tie wraps, PN 6015756. Insert the two bare terminals from alternator overlay wiring harness, PN 4362343, as shown in Figure 6-B as follows: NOTE: THE 4362343 ALTERNATOR OVERLAY HARNESS WAS MANUFACTURED WITH THE RED AND BLACK WIRES REVERSED. THEREFORE, IT WILL BE NECESSARY TO INSTALL THE BLACK WIRE (LABELED RED) INTO CAVITY #39 (RED WIRE PREVIOUSLY REMOVED), AND THE RED WIRE (LABELED BLACK) INTO CAVITY #33 (BLACK WIRE PREVIOUSLY REMOVED). FAILURE TO REVERSE THESE TWO WIRES WILL RESULT IN THE AMMETER SHOWING THE OPPOSITE CHARGE INDICATION. a. Red wire into cavity #33 (ammeter) - (labeled as black wire). b. Black wire into cavity #39 (ammeter) - (labeled as red wire). 6. Install wiring assembly, PN 4362343, alternator output terminal to new 78 amp alternator. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2022 FIGURE 6A1 7. Connect the battery positive lead and the headlamp and dash wiring assembly lead to those of the alternator overlay wiring assembly, PN 4362343, as shown in circled view of Figure 6-A. 8. Reinstall instrument panel half, then engine compartment half of bulkhead connector and torque to 40 inch pounds. 9. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 10. Reinstall engine cover. POLICY: Reimbursable within the provisions of the warranty and repair manual. TIME ALLOWANCE: Labor Operation No. 14-70-17-94 - All 2.5 Hrs. Optional Equipment: 14-70-17-60 - Carter Thermoquad Carburetor 0.5 Hrs. 14-70-17-61 - With Auxiliary A/C - Without Elec. 0.7 Hrs. Rear Window Defroster 14-70-17-62 - Without Auxiliary A/C 0.3 Hrs. 14-70-17-63 - With Auxiliary A/C - Without 0.4 Hrs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2023 Power Windows FAILURE CODE: AM - Authorized Modification Part List VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 22 GALLON FUEL TANK PACKAGE PART NO. 4397611 QTY PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075432 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Seal - Fuel Tank Gauge 3404451 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 36 GALLON FUEL TANK PACKAGE PART NO. 4397612 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075436 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Gasket - Fuel Tank Sending Unit 4115209 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2024 *It may be necessary to order clamp separately on early released packages. PARTS LIST FUEL PRESSURE REGULATOR PACKAGE FOR 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO.4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 PARTS LIST 78 AMP ALTERNATOR PACKAGE FOR 1981-1985 B MODEL TRUCKS WITH 5.2L OR 5.9L ENGINES PACKAGE PART NO. 4397615 QTY. PART NAME PART NO. 1 78 AMP Alternator Assembly - Complete 4111204 1 Alternator Overlay Wiring Harness 4362343 4 Tie Wrap 6015756 1 Gasket - Bulkhead Connector 4055399 FIGURE 4B - Mounting Fuel Resevoir/Filter 1. Fuel Filter/ Reservoir - 4418012 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2025 2. Screw - Self Tapping - 6022777 (2 Req.) 3. Tube Assy - Fuel Pump to Reservoir - 4306968 4. Return Hose & Sleeve Assy - 4418006 5. Hose Clamps - 6500650 (2 Req.) - 1/4" 6. Hose-Fuel Pump Outlet to Reservoir Inlet - 4203576 7. Hose-Reservoir Outlet to Carburetor or Regulator Fuel Tube - 4203576 8. Hose Clamps - 6500651 (4 Req.) - 5/16" Included but not shown: 2 piece Convolute Tubing - 4279993 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1 SCREW & WASHER - 6022254 2 REGULATOR BRACKET - 4418010 3 REGULATOR - 4418OD9 4 TUBE - REGULATOR TO CARB - 4418008 5 TUBE - RESERVOIR HOSE TO REGULATOR - 4418014 6 SCREW (2 EA.) - REGULATOR TO BRACKET - 6033066 7 CLAMP (5116) - 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 182985 > Jun > 85 > ECM - Warm Surge At Steady Speed Powertrain Control Module: Customer Interest ECM - Warm Surge At Steady Speed Models 1985 Trucks Equipped With 5.2L-2BBL Engine, O2 Feedback Carburetor System & Automatic Transmission With California Emissions Package Subject Warm Surge at Steady Speed Index DRIVEABILITY Date June 24, 1985 No.. 18-29-85 SYMPTOM/CONDITION Vehicle will exhibit a surge at steady speeds with engine at full operating temperature. PARTS REQUIRED Driveability Package PN 4397618 Contains: 1 Vacuum Delay Valve PN 4173433 1 Hose Routing Label PN 4179843 Must be ordered separately: 1 ESA Module PN 4289977 1 CVSCC PN 4095231 1 Authorized Modification Label PN 4275086 REPAIR PROCEDURE 1. Remove existing ESA module (PN 4289637) and install supplied ESA module, PN 4289977. 2. Drain coolant and remove existing CVSCC (coolant vacuum switch cold closed) and install supplied CVSCC, PN 4095231. 3. Cut one 1-1/2" section of 3/16" vacuum hose, PN 4105167 (serviced in 50 foot rolls). 4. Install the 1-1/2" section of 3/16" hose on the natural colored end of the vacuum delay valve, PN 4173433, supplied in package. 5. The EGR solenoid is mounted on the fender shield (right side of engine compartment). It can be identified by a "white" right angle vacuum connector. Remove the white right angle vacuum connector on the EGR solenoid and install the delay valve assembly on the EGR solenoid. The 1-1/2" piece of 3/16" hose is attached in place of the removed white right angle connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Customer Interest for Powertrain Control Module: > 182985 > Jun > 85 > ECM - Warm Surge At Steady Speed > Page 2030 FIGURE 1 - Vacuum Delay Valve - Attachment Procedure The white right angle connector is then attached to the orange colored side of the vacuum delay valve (Figure 1). 6. Wipe existing hose routing label clean. Install hose routing label, PN 4179843, supplied in package over the original label. FIGURE 2 7. Type Authorized Modification Label, PN 4275086, as shown in Figure 2 and install next to the VECI label. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 08-15-61-90 Trucks 0.5 Hrs. Vans 0.6 Hrs. FAILURE CODE: AM - Authorized Modification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2036 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2037 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2038 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2039 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2040 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2041 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2042 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2043 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2044 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2045 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2046 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2047 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2048 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2049 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2050 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock Technical Service Bulletin # 181985A Date: 851201 Fuel System - Vapor Lock Models 1981-1985 Van & Wagon Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 20, 1985 No. 18-19-85 REVISION A P-4782-C This bulletin supersedes Technical Service Bulletin #18-19-85 which should be removed from your files. The model application has been expanded to include 1981 and 1982 model years. SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING TWO PART NUMBERS: Vapor Lock Package With 22 Gallon Fuel Tank PN 4397611 Vapor Lock Package With 36 Gallon Fuel Tank PN 4397612 ADDITIONAL PARTS INFORMATION ON NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 All vehicles equipped with dual air conditioning, without electrically heated rear window defroster, and with 60 amp alternator must order the following package in addition to the vapor lock package. If vehicle is equipped with a 114 amp alternator, do not order this package or make any changes to the charging system. 1 78 AMP Alternator Package PN 4397615 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2055 Refer to parts list for contents of each package. Must be ordered separately: 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. REPAIR PROCEDURE A.Engine Compartment Harness Pn 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1A - ENGINE COMPARTMENT WIRING 3. Remove engine cover. Install the bare eyelet terminal of overlay harness, PN 4362295, to the negative terminal of the ignition coil as shown in Figure 1-A. FIGURE 1B - ENGINE COMPARTMENT WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2056 4. Route and secure the engine overlay harness, PN 4362295, along the existing main engine wiring harness using the existing wiring clips and two tie wraps, PN 6015756 (Figure 1-B). FIGURE 1C - ENGINE COMPARTMENT WIRING 5. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness to the bulkhead connector using the existing wiring clips and three tie wraps, PN 6015756 (Figure 1-C). Loop and tape any excess wire of the engine overlay harness. FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 6. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar multi-purpose grease PN 4318063, and snap into cavity #14 of the engine side of the bulkhead connector (Figure 1-D). B.Instrument Panel Harnesses Pn 4362289, All Models Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2057 FIGURE 2A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) 1. Remove instrument panel left lower trim panel. 2. Insert two bare terminals from instrument panel overlay harness, PN 4362289, into the instrument panel side of the bulkhead connector (Figure 2-A). a. Gray with black tracer wire into cavity #14. b. Dark green wire into cavity #13. INSTRUMENT PANEL WIRING 3. Secure bare eyelet ground terminal (white with black tracer wire) from instrument panel overlay harness, PN 4362289, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). NOTE: CERTAIN VEHICLES ARE ALREADY EQUIPPED WITH THE GROUND SCREW. IF SO, DISCARD THE SUPPLIED SCREW. FIGURE 2C - INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2058 FIGURE 2D - INSTRUMENT PANEL WIRING 4. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-C). Install the extracted terminal (orange wire) into the natural colored 1-way connector supplied with instrument panel overlay harness, PN 4362289. Install the bare terminal (orange wire) from the instrument panel overlay harness, PN 4362289, into the vacated cavity in the ignition switch connector. Reconnect the natural colored 1-way connectors supplied with the instrument panel overlay harness, PN 4362289, and reconnect the ignition switch connectors (Figure 2-C and 2-D). FIGURE 2E - TYPICAL CONTROL MODULE MOUNTING 5. Connect the control (auto shut-down) module, PN 5226640, to the natural colored 8-way connector from instrument panel overlay harness, PN 4362289. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2059 FIGURE 2D - INSTRUMENT PANEL WIRING FIGURE 2F - INSTRUMENT PANEL WIRING 6. Route the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289, to the back of the brake bracket for mating in a later step (Figures 2-B, 2-D, and 2-F). Secure instrument panel overlay harness, PN 4362289, using tie wrap, PN 6015756, to keep it clear of any possible interferences. Only one of the following installation procedures (Step 7) will be used. Take notice of which one applies to the vehicle being repaired. 7. Without Auxiliary Air Conditioning and/or Heater - Jumper Harness PN 4362291 a. Remove instrument panel hood and bezel assembly and remove radio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2060 FIGURE 2D - INSTRUMENT PANEL WIRING b. Route instrument panel jumper harness, PN 4362291, from the back of the brake bracket to the existing 3-way red molded connector. Secure by using existing wiring clips (Figure 2-D). c. Insert the bare bullet terminal (black with white tracer wire) from instrument panel jumper harness, PN 4362291, into the existing 3-way red molded connector from the main instrument panel wiring harness (Figure 2-D). d. Mate the orange colored 1-way connector from instrument panel jumper harness, PN 4362291, to the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). e. Reinstall instrument panel hood and bezel assembly and install radio. FIGURE 2F - INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater and Power Windows - Jumper Harness PN 4362292 a. Disconnect from each other, the two existing brown colored 1-way connectors located near the left instrument panel vent (Figure 2-F). Reconnect these two brown colored 1-way connectors to the two brown colored 1-way connectors from instrument panel jumper harness, PN 4362292 (Figure 2-F). b. Mate the orange colored 1-way connector from the instrument panel jumper harness, PN 4362292, to the orange colored 1-way connector from instrument panel overlay harness, PN 4362289 (Figure 2-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2061 INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater Without Power Windows - Relay Harness PN 4362290 a. Remove instrument panel hood and bezel assembly. Remove radio. b. Install the ignition switch protection relay, PN 4162597, to the back of the brake bracket (mounting location shown in Figure 2-B) and attach instrument panel relay harness, PN 4362290, to relay. c. Secure bare eyelet ground terminal (white wire) from instrument panel relay harness, PN 4362290, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING d. Route the dark blue wire from the instrument panel relay harness, PN 4362290 to the existing 3-way red molded connector using existing wiring clips. Insert bullet terminal (dark blue wire) into red molded connector (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2062 INSTRUMENT PANEL WIRING e. Insert bare bullet terminal (red wire) from instrument panel relay harness, PN 4362290, into the existing 3-way yellow molded connector from the main instrument panel wiring harness (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING f. Mate the orange colored 1-way connector from instrument panel relay harness, PN 4362290, to the colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). g. Install the instrument panel left lower trim panel, instrument panel hood, bezel assembly and radio. C.In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Feed red and yellow molds of body wiring harness, PN 4362293, through slot in the crossmember. Remove existing screw for gauge unit ground. Install eyelet terminal of harness, PN 4362293 (and ground eyelet terminal of 36 gallon tank gauge/pump unit) and torque ground screw to 36 inch pounds. CAUTION: GROUND SCREW MUST BE TIGHTENED SECURELY TO OPERATE ELECTRIC PUMP AND GAUGE UNIT. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2063 FIGURE 3A - BODY WIRING FIGURE 3B - BODY WIRING Install red mold of body harness, PN 4362293, onto red stud of gauge/pump unit. Install yellow mold of harness, PN 4362293, onto black stud of gauge/pump unit (figure 3-a or 3-b). Install molded blade terminal of harness, PN 4362293, onto blade terminal of 22 gallon gauge unit only. NOTE: PREVIOUS GAUGE UNIT GROUND WILL NOT BE USED ON 22 GALLON GAUGE/PUMP UNIT. ON 36 GALLON GAUGE PUMP UNIT, THE GROUND WIRE ON HARNESS PN 4362293 WILL NOT BE USED. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. Set aside the rest of harness, PN 4362293, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. D.Body Wiring Harness Pn 4362293 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2064 FIGURE 3C - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2065 FIGURE 3-F - BODY WIRING 1. Vehicles With 36 Gallon Tank Route harness, PN 4362293, to the right (passenger) side of vehicle along the fuel line tubes and tie wrap (1). At right frame rail, route harness forward to next crossmember (Figures 3-C and 3-E). Tie wrap harness in three (3) places. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2066 FIGURE 3D - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2067 FIGURE 3-F - BODY WIRING Vehicles With 22 Gallon Tank Route harness, PN 4362293, along right frame rail following brake lines (Figures 3-D and 3-E). Tie wrap in two (2) places. NOTE: HARNESS MUST BE ABOVE SHOCK STRUT WITH EITHER 36 OR 22 GALLON TANK. 2. At crossmember, route harness to the left rail following existing brake lines and tie wrap in two (2) places. At left rail, route harness forward through access holes following existing brake lines. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2068 FIGURE 3-F - BODY WIRING NOTE: HARNESS SHOULD BE TIGHT IN THIS AREA THE WRAP IN FOUR (4) PLACES (FIGURE 3-E). 3. At engine compartment, route harness through existing speedometer cable clips to bulkhead connector. If excess wiring exists; loop, tie wrap (2), and install into existing clip (Figure 3-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2069 FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 4. Plug bare terminal of harness, PN 4362293, into cavity #13 of the bulkhead connector (Figure 1-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2070 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2071 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2072 FIGURE 9 - ELECTRIC FUEL PUMP WIRING DIAGRAMW/AUX A/C & HEATER-W/O POWER WINDOWS 5. For all vehicles except those which require a 78 amp alternator package: Reinstall instrument panel side, then engine compartment side of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURES 7, 8, OR 9 FOR OVERALL WIRING DIAGRAMS. E.Engine Compartment Fuel Reservoir/Filter Lnstallation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2073 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER 1. Using template, PN 4418011, mark and drill (from engine side of passenger side chassis rail) two (2) holes .290" diameter (L size drill) as shown in Figure 4-A. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2074 FIGURE 4B - Mounting Fuel Resevoir/Filter 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. NOTE: RUBBER SPLASH SHIELD MAY HAVE TO BE CUT OUT AROUND FUEL RESERVOIR. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube, PN 4306968 (Figure 4-B). 4. Install return hose assembly, PN 4418006, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end (Figure 4-B). 5. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 42O3576. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2075 FIGURE 4B - Mounting Fuel Resevoir/Filter 6. Install one 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the fuel pump outlet tube to the reservoir/filter inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). 7. Install the other 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 8. Tighten all hose clamps to 10 inch pounds. FIGURE 10 9. Type Authorized Modification Label, PN 4275086, as shown in Figure 10 and attach near VECI label. 10. For all models except 1981-1984 equipped with Carter Thermoquad 4BBL carburetor or dual air conditioning units without electrically Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2076 heated rear window defroster. Reconnect battery. Start the engine, and inspect the entire system for fuel leaks and proper wire and hose routing. 11. Reinstall engine cover. F.1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (Pn 4397 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6O22254, (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT, AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6O22254. THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2077 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference with nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose-to-regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. For all models except those equipped with dual air conditioning units, without electrically heated rear window defroster and with 60 amp alternator: 6. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 7. Reinstall engine cover. G.Vehicles Equipped With Dual Air Conditioning Units, Without Electrically Heated Rear Defroster, and With 60 Amp Alternator. I Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2078 HEADLAMP AND DASH WIRING ASSEMBLY 1. Disconnect the battery positive lead (single in-line connection) from the headlamp and dash wiring assembly (Figure 6-A). FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 2. Remove the following wires from the engine compartment side of the bulkhead connector (Figure 6-B). a. Red wire from cavity #39 (ammeter). b. Black wire from cavity #33 (ammeter). Cut off the terminals and wrap tape around each end of both wires to insure that shorting cannot occur. Then tape the wrapped wires back against the main harness. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2079 FIGURE 6-C - 78 AMP ALTERNATOR WIRING 3. Remove the alternator output wire (heavy gauge) from the 60 amp alternator (Figure 6-C). Cut the wire off leaving approximately three (3) inches of wire extending out of the main harness. Tape the end of the lead thoroughly. Then fold and tape the lead back against the main harness to prevent shorting. 4. Remove 60 amp alternator assembly and install 78 amp alternator assembly, PN 4111204, per the service manual alternator replacement procedure. HEADLAMP AND DASH WIRING ASSEMBLY Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2080 FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 5. Beginning at the bulkhead, route and connect the wiring assembly, PN 4362343, as shown in Figure 6-A. Use the existing clip for main harness and tie wrap with three (3) tie wraps, PN 6015756. Insert the two bare terminals from alternator overlay wiring harness, PN 4362343, as shown in Figure 6-B as follows: NOTE: THE 4362343 ALTERNATOR OVERLAY HARNESS WAS MANUFACTURED WITH THE RED AND BLACK WIRES REVERSED. THEREFORE, IT WILL BE NECESSARY TO INSTALL THE BLACK WIRE (LABELED RED) INTO CAVITY #39 (RED WIRE PREVIOUSLY REMOVED), AND THE RED WIRE (LABELED BLACK) INTO CAVITY #33 (BLACK WIRE PREVIOUSLY REMOVED). FAILURE TO REVERSE THESE TWO WIRES WILL RESULT IN THE AMMETER SHOWING THE OPPOSITE CHARGE INDICATION. a. Red wire into cavity #33 (ammeter) - (labeled as black wire). b. Black wire into cavity #39 (ammeter) - (labeled as red wire). 6. Install wiring assembly, PN 4362343, alternator output terminal to new 78 amp alternator. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2081 FIGURE 6A1 7. Connect the battery positive lead and the headlamp and dash wiring assembly lead to those of the alternator overlay wiring assembly, PN 4362343, as shown in circled view of Figure 6-A. 8. Reinstall instrument panel half, then engine compartment half of bulkhead connector and torque to 40 inch pounds. 9. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 10. Reinstall engine cover. POLICY: Reimbursable within the provisions of the warranty and repair manual. TIME ALLOWANCE: Labor Operation No. 14-70-17-94 - All 2.5 Hrs. Optional Equipment: 14-70-17-60 - Carter Thermoquad Carburetor 0.5 Hrs. 14-70-17-61 - With Auxiliary A/C - Without Elec. 0.7 Hrs. Rear Window Defroster 14-70-17-62 - Without Auxiliary A/C 0.3 Hrs. 14-70-17-63 - With Auxiliary A/C - Without 0.4 Hrs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2082 Power Windows FAILURE CODE: AM - Authorized Modification Part List VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 22 GALLON FUEL TANK PACKAGE PART NO. 4397611 QTY PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075432 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Seal - Fuel Tank Gauge 3404451 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 36 GALLON FUEL TANK PACKAGE PART NO. 4397612 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075436 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Gasket - Fuel Tank Sending Unit 4115209 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2083 *It may be necessary to order clamp separately on early released packages. PARTS LIST FUEL PRESSURE REGULATOR PACKAGE FOR 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO.4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 PARTS LIST 78 AMP ALTERNATOR PACKAGE FOR 1981-1985 B MODEL TRUCKS WITH 5.2L OR 5.9L ENGINES PACKAGE PART NO. 4397615 QTY. PART NAME PART NO. 1 78 AMP Alternator Assembly - Complete 4111204 1 Alternator Overlay Wiring Harness 4362343 4 Tie Wrap 6015756 1 Gasket - Bulkhead Connector 4055399 FIGURE 4B - Mounting Fuel Resevoir/Filter 1. Fuel Filter/ Reservoir - 4418012 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2084 2. Screw - Self Tapping - 6022777 (2 Req.) 3. Tube Assy - Fuel Pump to Reservoir - 4306968 4. Return Hose & Sleeve Assy - 4418006 5. Hose Clamps - 6500650 (2 Req.) - 1/4" 6. Hose-Fuel Pump Outlet to Reservoir Inlet - 4203576 7. Hose-Reservoir Outlet to Carburetor or Regulator Fuel Tube - 4203576 8. Hose Clamps - 6500651 (4 Req.) - 5/16" Included but not shown: 2 piece Convolute Tubing - 4279993 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1 SCREW & WASHER - 6022254 2 REGULATOR BRACKET - 4418010 3 REGULATOR - 4418OD9 4 TUBE - REGULATOR TO CARB - 4418008 5 TUBE - RESERVOIR HOSE TO REGULATOR - 4418014 6 SCREW (2 EA.) - REGULATOR TO BRACKET - 6033066 7 CLAMP (5116) - 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 182985 > Jun > 85 > ECM Warm Surge At Steady Speed Powertrain Control Module: All Technical Service Bulletins ECM - Warm Surge At Steady Speed Models 1985 Trucks Equipped With 5.2L-2BBL Engine, O2 Feedback Carburetor System & Automatic Transmission With California Emissions Package Subject Warm Surge at Steady Speed Index DRIVEABILITY Date June 24, 1985 No.. 18-29-85 SYMPTOM/CONDITION Vehicle will exhibit a surge at steady speeds with engine at full operating temperature. PARTS REQUIRED Driveability Package PN 4397618 Contains: 1 Vacuum Delay Valve PN 4173433 1 Hose Routing Label PN 4179843 Must be ordered separately: 1 ESA Module PN 4289977 1 CVSCC PN 4095231 1 Authorized Modification Label PN 4275086 REPAIR PROCEDURE 1. Remove existing ESA module (PN 4289637) and install supplied ESA module, PN 4289977. 2. Drain coolant and remove existing CVSCC (coolant vacuum switch cold closed) and install supplied CVSCC, PN 4095231. 3. Cut one 1-1/2" section of 3/16" vacuum hose, PN 4105167 (serviced in 50 foot rolls). 4. Install the 1-1/2" section of 3/16" hose on the natural colored end of the vacuum delay valve, PN 4173433, supplied in package. 5. The EGR solenoid is mounted on the fender shield (right side of engine compartment). It can be identified by a "white" right angle vacuum connector. Remove the white right angle vacuum connector on the EGR solenoid and install the delay valve assembly on the EGR solenoid. The 1-1/2" piece of 3/16" hose is attached in place of the removed white right angle connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Powertrain Control Module: > 182985 > Jun > 85 > ECM Warm Surge At Steady Speed > Page 2089 FIGURE 1 - Vacuum Delay Valve - Attachment Procedure The white right angle connector is then attached to the orange colored side of the vacuum delay valve (Figure 1). 6. Wipe existing hose routing label clean. Install hose routing label, PN 4179843, supplied in package over the original label. FIGURE 2 7. Type Authorized Modification Label, PN 4275086, as shown in Figure 2 and install next to the VECI label. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 08-15-61-90 Trucks 0.5 Hrs. Vans 0.6 Hrs. FAILURE CODE: AM - Authorized Modification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations Powertrain Control Module: Component Locations Electronic Ignition System Components On Firewall Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations > Component Locations > Page 2092 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 2095 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2101 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 2106 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations Coolant Temperature Sensor/Switch (For Computer): Component Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 2109 Coolant Temperature Sensor/Switch (For Computer): Connector Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Component Locations > Page 2110 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Coolant Temperature Switch Coolant Temperature Sensor/Switch (For Computer): Description and Operation Coolant Temperature Switch Fig. 4 Switches & sensors location. V8 engine On V8 engines the coolant switch is located on the front of the intake manifold, Fig. 4. It operates by supplying a signal to the computer when the engine coolant temperature is below 150~ F. This information is required to prevent a change in air fuel ratio until engine operation temperature is reached except there is no control of canister purging. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Coolant Temperature Switch > Page 2113 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature Sensor Description The coolant temperature sensor measures temperature of the engine coolant. The coolant temperature sensor is mounted in the thermostat housing or in water passage of intake manifold. The sensor monitors engine coolant (operating) temperature. It supplies the logic module with a voltage signal which varies with coolant temperature. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2118 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control Crankshaft Position Sensor: Service and Repair RWD W/ Electronic Spark Control Removal & Installation Removal 1. Disconnect vacuum line at distributor, if equipped. 2. Disconnect distributor pickup lead(s) at wiring harness connector, then remove distributor cap. 3. Mark position of rotor on distributor body and engine block surface so that distributor can be installed in the same position. 4. Remove hold-down and/or bolt and lift distributor from engine. Installation 1. If engine was cranked after distributor was removed from engine, rotate crankshaft to bring No. 1 piston up on its compression stroke and align timing mark on crankshaft pulley with ``O'' (TDC) mark on timing cover. 2. With distributor gasket or O-ring in place, hold distributor over mounting pad. 3. Turn rotor to a position just ahead of the No. 1 distributor cap terminal. 4. Install distributor, engaging distributor gear with camshaft drive gear on 6 cylinder engines. On V-8 engines, engage tang of distributor shaft with slot in oil pump drive gear. With distributor fully seated on engine, rotor should be under No. 1 cap terminal. 5. Install distributor hold-down and/or bolt, distributor cap, pickup lead(s) and vacuum line. 6. Adjust ignition timing to specifications found in the Tune Up section. Distributor Shaft & Bushing Wear Test 1. Remove distributor from vehicle and clamp distributor in a vise. Use extreme caution not to damage distributor. 2. Attach a dial indicator to housing so plunger rests against reluctor sleeve. 3. Place a wire loop around reluctor sleeve and hook a spring scale on the other end of the loop. Apply a 1-1/2 lb. pull toward dial indicator. Apply a 1 lb. pull away from dial indicator and read movement on indicator. 4. Movement must not exceed .006 inch. If movement exceeds limit, replace either housing or shaft to bring movement back within tolerance. Distributor Disassembly 1. Remove rotor and vacuum advance unit, if equipped Fig. 14. 2. Remove reluctor by prying up from bottom of reluctor using two screwdrivers with a maximum blade width of 7/16 in. Use care not to damage or distort reluctor teeth. 3. Remove two screws and lockwashers attaching lower plate to distributor housing, then lift out lower plate, upper plate and pickup coil as an assembly. Do not remove distributor cap clamp springs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 2121 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 4. On eight cylinder units, if distributor housing, shaft, reluctor sleeve or governor weights are to be replace, proceed as follows: a. Remove distributor shaft retaining pin and slide retainer off end of shaft. b. If necessary, use a file to clean burrs from around pin hole area on shaft, then remove lower thrust washer. c. Push shaft upward and remove from distributor housing. Distributor Assembly Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 2122 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 1. Lubricate and test operation of governor weights. Inspect weight springs for distortion and bearing surfaces and pins for damage. 2. Lubricate upper thrust washer and install onto shaft. Install shaft into housing. 3. On eight cylinder units, install distributor shaft retainer and pin, Fig. 14. 4. On all units, install lower plate, upper plate and pickup coil assembly. 5. Attach vacuum advance unit to pickup plate, then install vacuum advance unit attaching screws and washers. 6. Position reluctor keeper pin into place on reluctor sleeve, then slide reluctor down reluctor sleeve and press firmly into position. Install keeper pin. 7. Lubricate felt pad located in top of reluctor sleeve with one drop of light engine oil, then install rotor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 2123 Crankshaft Position Sensor: Service and Repair RWD W/O Electronic Spark Control Removal & Installation Removal 1. Disconnect vacuum line at distributor, if equipped. 2. Disconnect distributor pickup lead(s) at wiring harness connector, then remove distributor cap. 3. Mark position of rotor on distributor body and engine block surface so that distributor can be installed in the same position. 4. Remove hold-down and/or bolt and lift distributor from engine. Installation 1. If engine was cranked after distributor was removed from engine, rotate crankshaft to bring No. 1 piston up on its compression stroke and align timing mark on crankshaft pulley with ``O'' (TDC) mark on timing cover. 2. With distributor gasket or O-ring in place, hold distributor over mounting pad. 3. Turn rotor to a position just ahead of the No. 1 distributor cap terminal. 4. Install distributor, engaging distributor gear with camshaft drive gear on 6 cylinder engines. On V-8 engines, engage tang of distributor shaft with slot in oil pump drive gear. With distributor fully seated on engine, rotor should be under No. 1 cap terminal. 5. Install distributor hold-down and/or bolt, distributor cap, pickup lead(s) and vacuum line. 6. Adjust ignition timing to specifications found in the Tune Up section. Distributor Shaft & Bushing Wear Test 1. Remove distributor from vehicle and clamp distributor in a vise. Use extreme caution not to damage distributor. 2. Attach a dial indicator to housing so plunger rests against reluctor sleeve. 3. Place a wire loop around reluctor sleeve and hook a spring scale on the other end of the loop. Apply a 1-1/2 lb. pull toward dial indicator. Apply a 1 lb. pull away from dial indicator and read movement on indicator. 4. Movement must not exceed .006 inch. If movement exceeds limit, replace either housing or shaft to bring movement back within tolerance. Distributor Disassembly 1. Remove rotor and vacuum advance unit, if equipped Fig. 14. 2. Remove reluctor by prying up from bottom of reluctor using two screwdrivers with a maximum blade width of 7/16 in. Use care not to damage or distort reluctor teeth. 3. Remove two screws and lockwashers attaching lower plate to distributor housing, then lift out lower plate, upper plate and pickup coil as an assembly. Do not remove distributor cap clamp springs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 2124 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 4. On eight cylinder units, if distributor housing, shaft, reluctor sleeve or governor weights are to be replace, proceed as follows: a. Remove distributor shaft retaining pin and slide retainer off end of shaft. b. If necessary, use a file to clean burrs from around pin hole area on shaft, then remove lower thrust washer. c. Push shaft upward and remove from distributor housing. Distributor Assembly Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 2125 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 1. Lubricate and test operation of governor weights. Inspect weight springs for distortion and bearing surfaces and pins for damage. 2. Lubricate upper thrust washer and install onto shaft. Install shaft into housing. 3. On eight cylinder units, install distributor shaft retainer and pin, Fig. 14. 4. On all units, install lower plate, upper plate and pickup coil assembly. 5. Attach vacuum advance unit to pickup plate, then install vacuum advance unit attaching screws and washers. 6. Position reluctor keeper pin into place on reluctor sleeve, then slide reluctor down reluctor sleeve and press firmly into position. Install keeper pin. 7. Lubricate felt pad located in top of reluctor sleeve with one drop of light engine oil, then install rotor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Charge Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Charge Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2129 Charge Temperature Switch Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Charge Temperature Sensor <--> [Intake Air Temperature Sensor] > Component Information > Specifications > Page 2130 Charge Temperature Sensor: Description and Operation Fig. 4 Switches & sensors location. V8 engine The CTS, Fig. 4, is used on eight cylinder engines and is located in the intake manifold No. 8 runner on eight cylinder engines. When the incoming air fuel mixture is below 60° F., the CTS will close, allowing no EGR timer function, no EGR valve operation and the air injection directed upstream into the exhaust manifold. When incoming air-fuel mixture is above 60° F., the CTS will open allowing EGR timer to expire, the EGR valve to operate and air injection switched downstream into the exhaust system. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Charge Temperature Switch <--> [Intake Air Temperature Switch] > Component Information > Locations Charge Temperature Switch: Locations Engine Mounted Switches & Sensors. Upper RH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Component Locations Detonation (Knock) Sensor: Component Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Component Locations > Page 2138 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Page 2139 Detonation (Knock) Sensor: Description and Operation Fig. 12 Detonation sensor location. V8 engine The detonation sensor, Fig. 12, is used on V8 engines only and is located in the intake manifold. It signals the computer when detonation occurs so that the ignition timing can be retarded. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications Manifold Pressure/Vacuum Sensor: Specifications All models with TBI. Apply 5" (125mm) Hg to unit and record output voltage. Apply 20" (500mm) Hg to unit, the difference in voltage should be 2.3 - 2.9. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2143 Manifold Pressure/Vacuum Sensor: Locations Combustion Control Computer Location. Upper RH Side Of Engine Applicable to: 1981-84 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 2144 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 7 Spark control computer & vacuum transducer location. V8 engine The vacuum transducer is located on the computer and it provides the computer with information on engine vacuum, Fig. 7. It is used to control spark advance and air fuel ratios. And indicates engine load. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations Oxygen Sensor: Locations Engine Mounted Switches & Sensors. Lower RH Side Of Engine Applicable to: V8 Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2150 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2151 Oxygen Sensor: Description and Operation Fig. 7 Spark control computer & vacuum transducer location. V8 engine To provide the EFC system with an indication of the exhaust gas composition, an oxygen sensor is threaded into the exhaust manifold and is exposed directly to exhaust gas stream, Fig. 7. The sensor is sensitive to the presence of or lack of oxygen. With an oxygen deficiency in the exhaust gas, outside oxygen diffuses through the sensor, acting as an electrolyte and generating a voltage. The oxygen sensor is basically a galvanic battery consisting of a cylindrical electrolyte element of zirconium dioxide which is coated inside and out with platinum. The outer platinum electrode is exposed to atmosphere, while the inner is exposed to the hot exhaust gases. A porous ceramic (spinel) coating protects the platinum against damage. When heated to operating temperature by the hot exhaust gases, the sensor generates a voltage. If the oxygen is high, a low voltage (below .45 volts) will be produced. When the oxygen content is low (rich mixture), a high voltage (.45 to 1 volt) will be produced. This relationship between available oxygen and sensor output voltage causes the sensor to function as a rich-lean switch. The sensor output voltage is used by the Feedback Carburetor Controller to calculate and adjust the air-fuel mixture as needed for optimum catalytic converter operation. The sensor's internal impedance, output voltage and time response are all functions of temperature. This temperature dependency is important during cold starts and other low temperature operating modes. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Throttle Body Temperature Sensor] > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Carburetor Switch <--> [Throttle Full Close Switch] > Component Information > Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Carburetor Switch <--> [Throttle Full Close Switch] > Component Information > Locations > Page 2158 Carburetor Switch: Description and Operation Fig. 4 Switches & sensors location. V8 engine The carburetor switch, Fig. 4, is located on the end of the idle stop and it signals the computer when the engine is at idle. Whenever the curb idle screw touches the carburetor switch, there will be no additional advance from the vacuum transducer or changing of the carburetor air fuel ratio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2163 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vacuum Switch > Component Information > Description and Operation Vacuum Switch: Description and Operation Fig. 7 Spark control computer & vacuum transducer location. V8 engine The vacuum transducer is located on the computer and it provides the computer with information on engine vacuum, Fig. 7. It is used to control spark advance and air fuel ratios. And indicates engine load. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Distance Sensor <--> [Vehicle Speed Sensor] > Component Information > Diagrams > Diagram Information and Instructions Distance Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Distance Sensor <--> [Vehicle Speed Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2171 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Throttle Body Temperature Sensor] > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Carburetor Switch <--> [Throttle Full Close Switch] > Component Information > Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Carburetor Switch <--> [Throttle Full Close Switch] > Component Information > Locations > Page 2178 Carburetor Switch: Description and Operation Fig. 4 Switches & sensors location. V8 engine The carburetor switch, Fig. 4, is located on the end of the idle stop and it signals the computer when the engine is at idle. Whenever the curb idle screw touches the carburetor switch, there will be no additional advance from the vacuum transducer or changing of the carburetor air fuel ratio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2183 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vacuum Switch > Component Information > Description and Operation Vacuum Switch: Description and Operation Fig. 7 Spark control computer & vacuum transducer location. V8 engine The vacuum transducer is located on the computer and it provides the computer with information on engine vacuum, Fig. 7. It is used to control spark advance and air fuel ratios. And indicates engine load. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Distance Sensor <--> [Vehicle Speed Sensor] > Component Information > Diagrams > Diagram Information and Instructions Distance Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Distance Sensor <--> [Vehicle Speed Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2191 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Air Diverter Valve > Component Information > Locations Air Diverter Valve: Locations LH Side Of Engine Applicable to: 1984-85 V8 Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Air Diverter Valve > Component Information > Description and Operation > Diverter Valve Air Diverter Valve: Description and Operation Diverter Valve Fig. 3 Diverter valve The diverter valve, Fig. 3, prevents backfire in the exhaust system during sudden deceleration. When the throttle is suddenly closed at the beginning of deceleration, the air/fuel mixture becomes too rich to burn. When the mixture reaches the exhaust area and combines with the injector air, it becomes burnable, and the next firing of the engine will ignite the mixture. When the diverter valve senses this sudden increase in intake manifold vacuum, the valve opens, allowing air to pass from the air pump, through the valve and silencer, and to the atmosphere. A pressure relief valve, integral with the diverter valve, controls system pressure by diverting excessive pump output at high engine speeds to the atmosphere through the silencer. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Air Diverter Valve > Component Information > Description and Operation > Diverter Valve > Page 2199 Air Diverter Valve: Description and Operation Relief Valve Fig. 5 Switch/relief valve This valve, Fig. 5, serves two purposes. The valve directs the flow or air injection either to the exhaust port location or to the downstream injection point. the valve also regulates system pressure by controlling the output of the air pump at high engine speeds. When pump pressure reaches a predetermined level, some of its output is vented to the atmosphere through the silencer. The switch/relief valve is controlled by manifold vacuum with either a CCEVS and/or a vacuum solenoid. When the engine is cold, a manifold vacuum signal is sent to the valve and air injection is directed to the exhaust ports. When the engine warms up, the CCEVS or EGR solenoid shuts off the manifold vacuum signal to the valve. A bleed orifice in the vacuum line to the valve allows the vacuum signal to go to zero. Without a vacuum signal, the valve directs most of the pump output to the downstream location. Slots in the valve seat allow a small amount of air to be injected to the exhaust ports at all times. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Air Diverter Valve > Component Information > Description and Operation > Page 2200 Air Diverter Valve: Testing and Inspection Failure of the diverter valve will be indicated by excessive noise. Either the diverter valve or relief valve has failed if air escapes from the silencer at engine idle speeds. The diverter valve is not serviceable and must be replaced if defective. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Air Diverter Valve > Component Information > Service and Repair > Diverter Valve Replacement Air Diverter Valve: Service and Repair Diverter Valve Replacement 1. Remove air and vacuum hoses from diverter valve. On some models, the air hose is clamped to a fitting on the diverter valve. 2. Remove valve attaching screws, then the valve. 3. Remove gasket material from valve and mounting surface. 4. Reverse procedure to install, using a new gasket. Torque attaching screws to 125 inch lbs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Air Diverter Valve > Component Information > Service and Repair > Diverter Valve Replacement > Page 2203 Air Diverter Valve: Service and Repair Relief Valve, Replace 1. Remove air hose from relief valve. 2. Remove valve attaching screws, then the valve. 3. Remove gasket material from valve and mounting surface. 4. Reverse procedure to install, using a new gasket. Torque attaching screws to 125 inch lbs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Air Diverter Valve > Component Information > Service and Repair > Diverter Valve Replacement > Page 2204 Air Diverter Valve: Service and Repair Switch/Relief Valve, Replace 1. Remove air and vacuum hoses from the switch/relief valve. 2. Remove valve attaching screw, then the valve. 3. Remove gasket material from valve and mounting surface. 4. Reverse procedure to install, using a new gasket. Torque attaching screws to 125 inch lbs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Air Injection Check Valve > Component Information > Locations Air Injection Check Valve: Locations Upper LH Side Of Engine Applicable to: 1984-85 V8 Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Air Injection Check Valve > Component Information > Locations > Page 2208 Air Injection Check Valve: Description and Operation A check valve, located in the injection tube assemblies leading to the exhaust manifolds on 4, V6 and V8 cylinder engines and to the cylinder head and exhaust pipe on In-Line 6 cylinder engines, incorporates a one-way diaphragm to prevent hot exhaust gases from backing up into the hose and pump. In the event of drive belt failure, air hose ruptures, or abnormally high exhaust system pressure, the check valve will protect the system. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Air Injection Check Valve > Component Information > Locations > Page 2209 Air Injection Check Valve: Testing and Inspection To determine if the check valve has failed, remove the air hose from the valve inlet tube. Failure of the valve will be indicated by exhaust gas flow from the inlet tube. This valve is not serviceable, and must be replaced if defective. If the exhaust manifold injection tube assembly is leaking, remove tube assembly and replace gasket material. If the tube nut joint is leaking, retorque to 30 ft lbs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Air Injection Check Valve > Component Information > Locations > Page 2210 Air Injection Check Valve: Service and Repair 1. Release clamp and disconnect air hose from check valve inlet. 2. Remove screw(s) or tube nut attaching injection tube assembly to cylinder head, exhaust manifolds or exhaust pipe. On some 4 cyl. and V8 engines, there is also an injection tube bracket bolted to the intake manifold. 3. Remove injection tube assembly from engine. 4. Remove gasket material from cylinder head or exhaust manifold, and injection tube flanges. 5. Reverse procedure to install, using new gasket(s). Note the following torques: injection tube attaching screws, 200 inch lbs., on V8 and 6 cyl. or 125 inch lbs. on 4 cyl. engines; injection tube to intake manifold bracket and tube nut, 30 ft lbs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Air Injection Control Valve > Component Information > Description and Operation Air Injection Control Valve: Description and Operation Fig. 6 Coolant vacuum switch cold open (CVSCO) The CVSCO,Fig. 6, provides manifold vacuum to the system after a cold start until engine coolant temperature reaches a predetermined level. After the coolant temperature reaches this level, the switch closes and vacuum is cut-off from the air switching system. The CVSCO is mounted in the thermostat housing. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Air Injection Control Valve > Component Information > Testing and Inspection > Air Switching Valve Air Injection Control Valve: Testing and Inspection Air Switching Valve Failure of the air switching valve is indicated when the valve receives a vacuum signal, but does not shut off air to the downstream injection point. This valve is not serviceable and must be replaced if defective. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Air Injection Control Valve > Component Information > Testing and Inspection > Air Switching Valve > Page 2216 Air Injection Control Valve: Testing and Inspection Switch/Relief Valve Failure of the switch/relief valve is indicated when vacuum is applied to the valve and air injection is not directed upstream (to the exhaust manifold crossover tube), or if air is injected both upstream and downstream. If the relief valve fails, air will escape from the silencer at engine idle speed. This valve is not serviceable and must be replaced if defective. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Air Injection Control Valve > Component Information > Testing and Inspection > Page 2217 Air Injection Control Valve: Service and Repair 1. Remove air and vacuum hoses from air switching valve. 2. Remove valve attaching screws, then the valve. 3. Remove gasket material from valve and mounting surface. 4. Reverse procedure to install, using a new gasket. Torque attaching screws to 125 inch lbs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Air Injection Pump > Component Information > Locations Air Injection Pump: Locations Front Of Engine Applicable to: 1984-85 V8 Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Air Injection Pump > Component Information > Locations > Page 2221 Air Injection Pump: Testing and Inspection EXCESSIVE BELT NOISE 1. Check for loose drive belt or seized air injection pump. EXCESSIVE PUMP NOISE 1. Inspect hoses for leaks and check that all connections are tight. 2. Check hoses for proper routing. 3. Check pump mounting bolts for looseness. 4. Verify proper operation of injection pump, check valve, switch/relief valve and diverter valve. A new air pump may emit a ``chirping'' noise. This noise should go away after a break-in period of approximately 1000 miles. NO AIR SUPPLY 1. Accelerate engine to 1500 RPM and observe air flow from hoses. 2. If air flow increases as engine speed increases, the pump is functioning normally. If not, proceed as follows: a. Check tension of drive belt. b. Inspect supply hose, fittings and diverter valve for air leaks. c. Verify proper operation of check valve and diverter valve. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Air Injection Pump > Component Information > Service and Repair > Air Injection Pump Replacement Air Injection Pump: Service and Repair Air Injection Pump Replacement WARNING Check condition and tension of air pump drive belt at least once every 12 months or 12,000 miles. The air pump should not be disassembled for any reason, nor should it ever be clamped in a vise. Do not use a hammer or pry bar on pump housing. Do not lubricate the pump. The small hole on top of some pumps is not an oil hole. If the engine is to be steam cleaned, mask off the centrifugal filter fan to prevent liquids from entering the pump. 1. Remove hoses from diverter, control valve, switch/relief valve or pump outlet elbow. 2. On 4-135 engines, remove air pump drive pulley shield from engine, if equipped. 3. On all models, loosen pump adjusting and pivot bolts and remove drive belt. 4. On vehicles equipped with six cylinder engine and A/C, it may be necessary to remove power steering belt. 5. Remove pulley and/or pump attaching bolts and the pump. 6. Remove pulley, valves, brackets and outlet elbow, if equipped, from pump. 7. Reverse procedure to install. Note the following torques: pump pulley screws, 95 inch lbs. on 6 cyl. and V8, 105 inch lbs. on 4 cyl.; pump mounting bolts, 29 ft lbs; bracket attachment bolts, 30 ft lbs; outlet elbow screws, 125 in lbs; air pump drive pulley shield attaching bolts, 125 in lbs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Air Injection Pump > Component Information > Service and Repair > Air Injection Pump Replacement > Page 2224 Air Injection Pump: Service and Repair Centrifugal Filter Fan, Replace Fig. 9 Removing centrifugal filter fan from injection pump To remove a damaged filter fan, insert needle nose pliers between the plastic filter fins and break the fan away from the hub, Fig. 9. Use caution to prevent fragments from entering the air intake hole. Do not insert screwdriver blade between pump and filter and do not attempt to remove the metal drive hub. To install the new filter fan, draw it into position using the pulley and bolts as tools. Tighten the bolts alternately to draw the fan down evenly, making sure that the outer edge of the fan slips into the housing. Some interference with the housing bore is normal. A new fan may make a ``squealing'' noise during initial operation. When the O.D. sealing lip has worn in (approximately 20-30 miles of operation), the noise should subside. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Air Injection Relief Valve > Component Information > Testing and Inspection Air Injection Relief Valve: Testing and Inspection Failure of the relief valve will be indicated by excessive noise and air pump output at the silencer ports in the valve body at engine idle speeds. The relief valve is not serviceable and must be replaced if defective. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Pulsair Valve, Secondary Air Injection > Component Information > Locations Pulsair Valve: Locations Upper LH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Pulsair Valve, Secondary Air Injection > Component Information > Description and Operation > Pulse Air Aspiration System Pulsair Valve: Description and Operation Pulse Air Aspiration System Fig. 10 Aspirator air valve The valve, Fig. 10, in this system uses exhaust pressure pulsations to draw air into the exhaust system to reduce CO and HC emissions. It draws fresh air from the ``clean'' side of the air cleaner and past a one-way spring loaded diaphragm. The diaphragm opens to permit fresh air to mix with the exhaust gases during negative pressure (vacuum) pulsations. When the pressure is positive, the diaphragm closes and no gases are allowed to flow past the valve. The aspirator valve operates most efficiently at idle and slightly past idle when the negative pulses are maximum. At higher speeds, the aspirator valve remains closed. Vehicles equipped with V8-318 engine and 1985-87 vehicles with 4-156 engine have two aspirators. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Pulsair Valve, Secondary Air Injection > Component Information > Description and Operation > Pulse Air Aspiration System > Page 2233 Pulsair Valve: Description and Operation Pulse Air Feeder (PAF) System Fig. 11 Pulse air feeder system This system, Fig. 11, used on some 1984---87 models, supplies secondary air into the exhaust system between the front and rear converters. This action aids oxidation of exhaust emissions in the rear catalytic converter. The pulse air feeder system consists of a main reed valve and a sub reed valve. A diaphragm, activated by pressure pulses in the crankcase, controls the main reed valve. The sub reed valve is controlled by pulsations in the exhaust system between the front and rear catalytic converters. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Pulse Air Feeder <--> [Pulsed Secondary Air Injection] > Component Information > Description and Operation Pulse Air Feeder: Description and Operation Fig. 11 Pulse air feeder system This system, Fig. 11, used on some 1984---87 models, supplies secondary air into the exhaust system between the front and rear converters. This action aids oxidation of exhaust emissions in the rear catalytic converter. The pulse air feeder system consists of a main reed valve and a sub reed valve. A diaphragm, activated by pressure pulses in the crankcase, controls the main reed valve. The sub reed valve is controlled by pulsations in the exhaust system between the front and rear catalytic converters. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Pulse Air Feeder <--> [Pulsed Secondary Air Injection] > Component Information > Description and Operation > Page 2237 Pulse Air Feeder: Service and Repair PULSE AIR FEEDER, REPLACE 1. Remove air deflector duct attaching screw and the duct from right side of radiator. 2. Remove carburetor protector shield. 3. Remove engine oil dipstick and dipstick tube. 4. Remove 3 pulse air feeder attaching bolts. 5. Raise and support vehicle. 6. Disconnect vacuum hoses from pulse air feeder, then remove feeder from vehicle. 7. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation The dual catalytic converters used on 6 cylinder and V8 engines, decrease HC and CO emissions or NOx emissions, or all three of these exhaust pollutants. The converters used in this system are tandem mounted. Oxidation Catalyst The oxidation catalytic converter contains a platinum coated, ceramic, honeycombed structure. Through a chemical reaction, the platinum oxidizes HC and CO and converts them to carbon dioxide and water vapor. Effective operation of this type of catalyst requires temperatures of 600° F or higher as well as an adequate supply of oxygen in the exhaust system. Oxidation catalysts will normally ``light off'' (start oxidation) within two minutes after the first start of a cold engine. Three-Way Catalyst The three-way catalytic converter contains rhodium which reduces or separates oxides of nitrogen (NOx) into nitrogen and oxygen. This action provides better exhaust emission control than is obtainable by using only exhaust gas recirculation, an oxidation catalyst or engine modifications. Its use allows richer air-fuel mixtures, more spark advance and less exhaust gas recirculation. All three improve both driveability and fuel economy. Effective catalytic control of all three pollutants is possible when the correct balance of excess CO is reached for reduction and excess oxygen is reduced. Therefore, it is necessary to maintain precise control of the air-fuel mixture entering the engine, keeping it very close to the stoichiometric range (chemically correct for theoretical complete combustion). The downstream catalyst, along with oxygen supplied by an air pump is used to remove the remaining HC and CO left after the exhaust gases have passed through the three-way catalyst. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Early Fuel Evaporation ( EFE ) > EFE Valve > Component Information > Description and Operation EFE Valve: Description and Operation This valve is vacuum actuated and is located between the right exhaust manifold and exhaust pipe, where it directs the majority of exhausts of exhaust gases through the left hand exhaust manifold. The CCEVS or CVSCO controls the manifold vacuum signal necessary to activate the heat valve. At coolant temperatures below a predetermined level, manifold vacuum is applied to the heat valve and all exhaust gas flow is directed to the left hand exhaust manifold. Above this temperature, no vacuum signal is applied to the heat valve and exhaust gases flow through both left and right hand manifolds. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Early Fuel Evaporation ( EFE ) > EFE Valve > Component Information > Description and Operation > Page 2245 EFE Valve: Service and Repair 1. Disconnect exhaust pipe from exhaust manifold. 2. Disconnect vacuum line from valve, then remove the valve assembly. 3. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Service Reminder Indicator Light <--> [Emissions Maintenance Light] > Emissions Maintenance Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Emissions Maintenance Lamp Relay: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Service Reminder Indicator Light <--> [Emissions Maintenance Light] > Emissions Maintenance Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2251 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Description and Operation Evaporative Check Valve: Description and Operation CARBURETED ENGINES All carbureted engines are equipped with rollover valve, which is designed to prevent fuel leakage if a vehicle is accidentally rolled over. The rollover valve is mounted in the top of the fuel tank. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Evaporative Emission Control Canister: Locations Charcoal Canister A sealed, maintenance free, charcoal canister is used on all engines and is located in the wheelwell area of the engine compartment. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 2259 Evaporative Emission Control Canister: Description and Operation All models use a maintenance free charcoal canister. The charcoal canister is used to store fuel vapors from the carburetor (if equipped} and fuel tank until they can be drawn into the intake manifold. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Valve <--> [EGR Control Solenoid] > Component Information > Locations EGR Control Valve: Locations Exhaust Gas Recirculation (EGR) System Components In Air Cleaner Housing Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations EGR Valve: Locations Exhaust Gas Recirculation (EGR) System Components Upper LH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 2267 EGR Valve: Testing and Inspection The CCEGR valve can be tested for proper operation by placing it in ice and cooling it to below 40° F. Using a suitable vacuum pump and gauge tool C-4207 or equivalent, apply vacuum of at least 10 inches Hg to valve nipple corresponding to the blue striped hose. If vacuum reading drops more than 1 inch in one minute, replace CCEGR valve. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Vacuum Amplifier, EGR > Component Information > Locations Vacuum Amplifier: Locations Exhaust Gas Recirculation (EGR) System Components Upper RH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Diagrams Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Diagrams > Page 2274 Positive Crankcase Ventilation: Description and Operation POSITIVE CRANKCASE VENTILATION SYSTEM (Typical). This system is used to eliminate emission of residual fumes and vapors from the crankcase by directing these fumes back through the combustion chamber. When the engine is running, air is drawn by manifold vacuum from the air cleaner through a hose, to the crankcase inlet air cleaner. From the crankcase inlet air cleaner, the air mixes with vapors in the rocker arm chamber and crankcase, and then drawn up through the PCV valve in the cylinder head cover to a hose connected to either the intake manifold or carburetor hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Diagrams > Page 2275 Positive Crankcase Ventilation: Testing and Inspection Fig. 30 Checking PCV valve vacuum Fig. 31 Checking vacuum at crankcase inlet filter (Typical). except 4 cylinder & V6-181 engines 1. With engine running at idle, proceed as follows: a. Remove PCV valve from rocker cover. If valve is not plugged, a hissing noise will be heard as air passes through the valve, and a strong vacuum will be felt at the valve inlet, Fig. 30. b. Reinstall PCV valve and remove crankcase inlet air filter. Loosely hold a piece of stiff paper over opening in rocker cover, Fig. 31. When crankcase pressure decreases after approximately one minute, the paper should be drawn firmly against the opening. 2. Stop engine and remove PCV valve. When valve is shaken, a clicking noise should be heard, indicating freedom of the valve mechanism. 3. If system passes tests in steps 1 and 2, no further service is required. If not, replace PCV valve and recheck system. Never attempt to clean an old PCV valve. 4. If, after a new PCV valve has been installed, the paper is not drawn against crankcase inlet air cleaner opening in rocker cover, the ventilator hose Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Diagrams > Page 2276 and passages in lower portion of carburetor must be cleaned. To clean hose and passages, proceed as follows: a. Clean carburetor hose with a suitable solvent and dry with compressed air. Do not allow hoses to remain in solvent for more than 1/2 hour. b. Remove carburetor and hand turn a 1/4 inch or smaller drill through the passages to dislodge any solid particles, then blow clean. It is not necessary to disassemble the carburetor for this procedure. 5. Clean the crankcase inlet air cleaner with a suitable solvent, then fill the filter with SAE 30 engine oil. 6. Clean or replace the carburetor air cleaner. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Diagrams > Page 2277 Positive Crankcase Ventilation: Service and Repair On 1982-84 six and eight cylinder light duty emissions cycle vehicles, check system operation every 15,000 miles, and replace PCV valve every 30,000 miles. On four cylinder and all 1985-87 light duty cycle vehicles, replace PCV valve every 52,500 miles. On 1980-84 heavy duty cycle vehicles and 1985-87 heavy duty cycle California vehicles and Federal vehicles with a single air pump, check system operation every 12,000 miles and replace PCV valve every 24, 000 miles. On 1985-87 heavy duty cycle vehicles with dual air pump, except California, replace PCV valve every 54,000 miles. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > Emissions Maintenance Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Emissions Maintenance Lamp Relay: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control Systems > Emissions Maintenance Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2283 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Thermostatic Air Cleaner > Thermostatic Air Cleaner Vacuum Motor > Component Information > Locations Thermostatic Air Cleaner Vacuum Motor: Locations Combustion Control Computer Location. Upper RH Side Of Engine Applicable to: 1981-84 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Orifice Spark Advance Control (OSAC) <--> [Vacuum Restrictor] > Component Information > Description and Operation Orifice Spark Advance Control (OSAC): Description and Operation The OSAC system is used on some vehicles to aid in the control of oxides of nitrogen (NOx). The system controls the vacuum to the vacuum advance actuator of the distributor. A tiny orifice is incorporated in the OSAC valve which delays the change in ported vacuum to the distributor by about 17 seconds (27 seconds on some models) when going from idle to part throttle. When going from part throttle to idle, the change in ported vacuum to the distributor will be instantaneous. The valve will only delay the ported vacuum signal when the ambient temperature is about 60° F. or above. Vacuum is obtained by a vacuum tap just above the throttle plates of the carburetor. This type of tap provides no vacuum at idle, but provides manifold vacuum as soon as the throttle plates are opened slightly. Proper operation of this valve depends on air tight fittings and hoses and on freedom from sticking or plugging due to deposits. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pump Pressure ............................................................................................................................ ........................................................ 4.75 psi - 6.25 psi Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package Technical Service Bulletin # 250485 Date: 850506 High Altitude Conversion Package Models 1985 Light Duty Domestic Trucks Subject High Altitude Conversion Packages & Adjustment for Improved Engine Performance Index EMISSIONS Date May 6, 1985 No.. 25-04-85 P-1522-C Packages are now available to accommodate a customer who wishes to convert his 1985 low altitude vehicle for improved high altitude (over 4,000 feet above sea level) engine performance. Vehicles with the low altitude package transferred to service in high altitude areas may exhibit undesirable driveability. However, the installation of a high altitude conversion package is voluntary and at the customer's expense. The high altitude field conversion packages and procedures outlined below have been authorized on the following 1985 non-altitude equipped engine families in service at altitudes above 4,000 feet above sea level. CONVERSION INSTRUCTIONS Sea Level to Altitude FIGURE 1 - Vehicle Emission Control Information Label IMPORTANT: IN SOME OF THE CONVERSION PROCEDURES YOU WILL BE REQUIRED TO INSTALL A NEW VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL PN 4275084. THIS LABEL HAS TWO AREAS THAT ARE IMPACT IMPRINTABLE WITH A TYPEWRITER (SEE FIGURE 1). If you are required to readjust timing, curb idle speed, or fast idle speed to a specification different than the original VECI label specification, then just type in the new specification after the subject operation. If you are asked to refer to the original VECI label specifications, type in on the right hand side of the label "Refer to Original VECI Label." Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2299 In every case where this label is used, type in after - AUTHORITY OF Technical Service Bulletin #25-04-85, and your dealer code below. Label PN 4275084 is available from Parts Supply. FIGURE 2 - Vehicle Emission Control Information Label The engine family chart below will help identify the appropriate parts to be installed by recording body style and engine family from the original VECI label. This chart cross references the EPA engine family with the engine application used in the accompanying instructions (refer to Figure 2). EPA Engine Family Engine Application (Found on VECI Label) 2.2L-2V Federal FCR2.2T2AAB6 2.2L-2V 50 States FCR2.2T2HBM9 2.6L-2V Federal FCR2.6T2AAB8 3.7L-1V Federal FCR3.7T1BBA0 5.2L-2V 50 States FCR5.2T2HBN1 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2300 5.2L-2V Federal FCR5.2T2BBF6 5.9L-4V Federal FCR5.9T4BBF1 POLICY: Information only 1985 2.2L-2V Light Duty Trucks All Models With Federal Emissions Package (49 States) Dodge Ram Van, Dodge Caravan, Plymouth Voy Consisting of: 1 - #211 Primary Main Jet PN 4293797 1 - #215 Secondary Main Jet PN 4240006 1 - #180 Primary High Speed Bleed PN 4342920 1 - #210 Secondary High Speed Bleed PN 4342921 1 - Carburetor Air Horn Gasket PN 4293846 INSTRUCTIONS FIGURE 1. Holley 5220 Primary Main Metering Jet #211 FIGURE 2. Holley 5220 Secondary Main Metering Jet #223 - Remove carburetor air horn. - Remove primary and secondary main metering jets. Refer to Figures 1 and 2. - Install #211 primary main metering jet PN 4293797. - Install #215 secondary main metering jet PN 4240006. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2301 FIGURE 3. Holley 5220 Primary High Speed Bleed #180 FIGURE 4. Holley 5220 Secondary High Speed Bleed #210 - Remove primary and secondary high speed bleeds. Refer to Figures 3 and 4. - Install #180 primary high speed bleed PN 4342920. - Install #210 secondary high speed bleed PN 4342921. FIGURE 5. Holley 5220 Power Valve Location - Turn power valve (Figure 5) two full turns counterclockwise (lean). - Reinstall air horn with new air horn gasket PN 4293846. Start engine and check for leaks. - Warm up engine and set idle speed to that specified on the VECI label. - Type in changes made on Emission Update Label PN 4275084 and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2302 1985 2.2L-2V Light Duty Truck Dodge Ram Van, Dodge Caravan & Plymouth Voyager Only Equipped With "50 States" Emission Package Consisting of: 1 - Carburetor (manual or automatic PN 4342891 transmission) Also order conversion hardware package. 1 - Hardware Package PN 4342950 Consisting of: 1 - Carburetor Base Gasket PN 4095975 1 - H.A.C. PN 4306202 1 - Hose Routing Diagram NPN 1 - Mounting Bracket (H.A.C.) PN 4105199 1 - H.A.C. Hose Harness NPN 3 - Mounting Screws NPN INSTRUCTIONS - Remove carburetor per instructions in appropriate engine performance/electrical shop manual. - Install new carburetor with new base gasket. FIGURE 6 - High Altitude Compensator Mounting - Install altitude compensator with bracket (Figure 6). - Install altitude compensator vacuum hose harness, route as shown in hose routing diagram (Figure 6). - Warm up engine. - Set engine idle speed to specified VECI label specification. - Set high fast idle on Step 3 (lowest) to specification. - Double check hose routing and installation of fuel lines. - Type in changes made on the Emission Update Label PN 4275084 and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2303 1985 2.6L-2V Light Duty Truck All Models With Federal Emissions Package (49 States) Consisting of: 1 - Carburetor Jet Kit PN MD088294 containing: #110 Primary Main Jet #175 Secondary Main Jet #100 Primary Air Bleed Jet #120 Secondary Air Bleed Jet 1 - Float Chamber Cover Gasket PN MD608639 1 - Choke Cover Screw Kit PN MD606977 1 - Carburetor Flange Gasket PN MD025344 INSTRUCTIONS - Remove carburetor from engine and take off air horn per instructions in appropriate service manual. FIGURE 7 - Mikuni Jet Locations - Remove primary and secondary main jets as shown in Figure 7. - Install #110 primary main jet and #175 secondary main jet in the primary and secondary pedestals. - Reinstall air horn on carburetor using new air horn gasket PN MD608639 and choke cover screw kit PN MD606977. FIGURE 8 - Mikuni Air Bleed Jet Locations - Remove primary and secondary air bleed jets shown in Figure 8. - Prepare carburetor for propane idle set by drilling out concealment plug. - Install #120 secondary air bleed jet and #100 primary air bleed jet. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2304 - Reinstall carburetor on engine using a new carburetor flange gasket, PN MD025344. - Remove vacuum controlled orificed tank vapor valve (VCOTV) and the vacuum/line(s) to the valve. - Remove the 3/16" tank vent line from the vapor canister and replace with 24" of 3/16" tank vent line and route directly to steel tank vent tube. - Remove the manifold vacuum line from the manifold vacuum tee (originally to the VCOTV) and cap the tee. - Remove the EGR delay valve at the corresponding EGR and carburetor ports and replace with 8" of bulk 3/16" vacuum line from stock. - Start engine and warm up to operating temperature. - Set idle rpm (curb) to 850 rpm and propane enriched rpm to 950 rpm. - Set throttle kicker rpm to 1050 rpm. FIGURE 9 - Authorized Modifications Label - Type in changes made on Authorized Modification Label, PN 4275086 (Figure 9), and affix to engine compartment next to VECI label. 1985 3.7L-1V Light Duty Trucks All Models With Federal Emission Package (49 States) Consisting of: 1 - #611 Main Metering Jet PN 3837520 1 - Carburetor Air Horn Gasket PN 4267140 INSTRUCTIONS - Remove carburetor. - Remove air horn from carburetor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2305 FIGURE 10 - Main Metering Jet Location - Remove existing main metering jet (Figure 10). - Install #611 main metering jet PN 3837520. - Reinstall air horn with new air horn gasket PN 4267140. - Drill out concealment plug and prepare carburetor for propane idle set. - Per instructions in appropriate service manual, perform a propane idle set. Reset the propane/curb idle speeds to 775/750 for manuals and 800/775 for automatics. - Reset HFI to 1600 on Step 2. - Reset choke vacuum kick to 0.120". - Reset idle solenoid speed to 850 rpm (manual transmission) or 875 (automatic transmission). - Type in changes made on Emission Update Label and affix in engine compartment next to VECI label. 1985 5.2L-2V Light Duty Trucks All Models With "50 States" Emissions Packages Consisting of: 1 - Carburetor PN 4306453 1 - EGR Valve PN 4094891 1 - EGR Valve Gasket PN 4287938 1 - Carburetor Gasket PN 4095970 INSTRUCTIONS Using procedures as outlined in the appropriate service manual, perform the following: - Remove existing carburetor. - Install replacement carburetor PN 4306453 and gasket. - Remove EGR valve and scrape off old gasket material. - Install replacement EGR valve PN 4094891 and new gasket PN 4287938. - Start engine and check for leaks. - Check and reset if necessary, curb idle, fast idle to VECI label specifications. - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2306 1985 5.2L-2V Light Duty Trucks All Models With Federal Emissions Package (49 States) Consisting of: 2 - Main Metering Jet #147 PN 4271983 1 - EGR Valve PN 4287678 1 - EGR Valve Gasket PN 4287938 1 - Carburetor Base Gasket PN 4095970 INSTRUCTIONS Per instructions in appropriate service manual, perform the following: - Remove carburetor from engine. - Remove air horn from carburetor. FIGURE 11 - Holley 2280 Main Metering Jets - Remove existing main metering jet (Figure 11). - Install main metering jets provided, PN 4271983. - Adjust vacuum kick to 0.150". - Adjust mechanical unloader to 0.280". - Remove EGR valve and scrape off old gasket material. - Install new EGR valve PN 4287678 with new gasket PN 4287938. - Start engine, check for leaks. - Prepare carburetor for propane idle set and reinstall on engine using gasket PN 4095970. - Start engine and check for leaks. - Perform propane idle adjustment to 700 rpm (curb idle) and 770 rpm (propane enriched idle). - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. 5.9L-4V Light Duty Trucks All Automatic Models With Federal Emissions Package Consisting of: 1 - Carburetor PN 4342807 1 - EGR Valve PN 4287659 1 - Carburetor Base Gasket PN 3698365 1 - EGR Valve Gasket PN 4287938 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2307 INSTRUCTIONS - Remove existing carburetor. - Install new carburetor PN 4342807 along with new carburetor base gasket PN 3698365. - Raise the rear wheels of the vehicle with the transmission in neutral. Rotate the rear wheels through one revolution and determine the axle ratio. - If the vehicle has a 3.55 or 4.10 axle, replace EGR valve with PN 4287659 and gasket PN 4287938. - Start engine and check for leaks. - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. 5.9L-4V Light Duty Trucks All Manual Models With Federal Emission Package Consisting of: 1 - Carburetor PN 4342807 1 - Carburetor Base Gasket PN 3698365 INSTRUCTIONS - Remove original carburetor. - Install replacement carburetor PN 4342807 using new base gasket PN 3698365. - Start engine and check for leaks. - Type in changes made on Emission Update Label PN 4275084 and affix to engine compartment next to original VECI label. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2308 Idle Speed: Technical Service Bulletins Propane Idle Adjustment - Determination Guidelines Models 1985 Model Year Vehicles Subject Guidelines For Determining the Use of Idle Mixture Adjustment Index FUEL Date 10/1/84 No.. 14-46-84 P-4283C This bulletin should serve as a guideline to help determine when a propane or "CO" method idle set is to be performed. The propane or "CO" method idle mixture adjustment should only be performed if it is determined necessary by the propane or "CO" method idle check in the respective year Driveability Test Procedure books or service manual. More specifically, propane or "CO" method idle mixture adjustment should only be used if an idle "problem" still exists after normal diagnosis has revealed no other faulty condition such as incorrect idle speed, incorrect basic ignition timing, faulty hose, or wire connections, etc. It is also important to make sure the EFC/ESA combustion computer system is operating properly. Adjustment of the idle mixture should also be performed after a major carburetor overhaul. A guideline of conditions for determining whether a propane or "CO" method idle set is needed is attached. The conditions listed below are affected by idle mixture adjustment: ^ Rough Idle Warm ^ Breakaway Sag-Light Throttle Tip In ^ Decel Die Out ^ After a Major Carburetor Overhaul The conditions listed below are not affected by idle mixture adjustment: ^ Spark Knock ^ Poor Fuel Economy ^ Road Load Surge ^ Decel Bucking ^ Long Cold Crank ^ Cold Start Die Out Time ^ After-Run (dieseling) ^ Lack of Power on ^ Cold Rough Idle Acceleration POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Page 2309 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Adjustments > Idle Mixture and Speed Adjustments Idle Speed: Adjustments Idle Mixture and Speed Adjustments 1981-86: Disconnect and plug canister control and EGR vacuum hoses. Remove PCV valve from grommet and allow it to draw underhood air. With ESC, ground carb switch and disconnect Oxygen sensor. 1981-82: Set idle speed screw to specification. Set cam to specified step. Set fast idle. 1983-88, 6 & 8 cyl. models with solenoids.: Turn A/C on, set blower to low, disconnect compressor clutch wire. Without A/C, apply battery voltage to solenoid. Adjust speed-up solenoid by removing adjusting screw and spring and inserting a one-eighth inch allen wrench into socket and turning. Set idle speed by adjusting screw on carb body. 1987-88 4cyl.: Energize radiator fan with a jumper wire. Remove PCV valve from grommet and disconnect vacuum kicker solenoid electrical lead. Disconnect oxygen sensor test connector on left fender shield. Adjust idle speed screw on top of solenoid to specified idle speed. Place fast idle cam on specified step and adjust to specified value. Disconnect idle solenoid electrical lead and set base idle to specified value. Other models: Set idle speed by turning screw on carb body. Set cam to specified step and adjust fast idle to specification. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Adjustments > Idle Mixture and Speed Adjustments > Page 2312 Idle Speed: Adjustments Idle Speed Adjustment Curb Idle Speed Adjustment 1. Disconnect and plug vacuum hose at EGR valve, ESA module, distributor or carburetor, as required. 2. On models equipped with carburetor ground switch, connect jumper wire between switch and ground. 3. On models not equipped with Spark Control Computer (SCC), disconnect and plug vacuum hose from carburetor at heated air temperature sensor and Orifice Spark Advance Control (OSAC) valve, if equipped. 4. On all models, disconnect and plug control hose at canister. 5. Remove PCV valve from cylinder head cover and allow to draw underhood air. 6. Connect tachometer, then start engine and allow to reach normal operating temperature. 7. On models less 1985 6280 carburetor, adjust Solenoid Idle Stop (SIS), if equipped, as follows: a. On 1983-84 models with A/C, turn on A/C and set blower on low, then disconnect A/C clutch wire. b. On 1983-84 models less A/C and all 1985-87 models, connect jumper wire between battery positive terminal and the SIS lead wire. Ensure correct jumper wire installation. Applying battery voltage to other than correct wire will damage the wiring harness. c. On all models, open throttle slightly to allow solenoid plunger to extend. d. On Holley models, remove adjusting screw and spring from solenoid, then insert 1/8 inch Allen wrench into the solenoid and adjust to correct engine RPM. e. On Carter models, turn adjusting screw on throttle lever to obtain correct engine RPM. f. On Rochester models, turn solenoid plunger screw to obtain correct engine RPM. g. Turn off A/C and reconnect clutch wire or remove jumper, if equipped. h. Install solenoid screw and spring, if equipped with Holley carburetor. 8. On models with 1985 6280 carburetor, adjust Solenoid Idle Stop (SIS) as follows: a. Disconnect and ground engine harness electrical connector from oxygen sensor. b. Allow engine to run at least five minutes, then connect a jumper wire between the battery positive terminal and SIS lead wire. Ensure correct jumper wire installation. Applying battery voltage to other than correct wire will damage the wiring harness. c. Open throttle slightly to allow solenoid plunger to extend. d. Remove adjusting screw and spring from solenoid, then insert a 1/8 inch allen wrench into the solenoid and adjust to correct engine RPM. e. Install screw and spring, then turn in screw until it bottoms out. 9. On 1983-84 models equipped with oxygen sensor feedback carburetors, proceed as follows: a. Disconnect electrical connector from oxygen sensor and ground connector. b. Remove and plug vacuum hose at vacuum transducer on SCC, then install suitable vacuum pump to vacuum transducer and apply 16 inches of vacuum. c. Allow engine to run for two minutes. If idle is not as specified, turn adjusting screw on solenoid to obtain correct RPM. 10. On 1983-84 models not equipped with oxygen sensor feedback carburetors and all 1985-87 model carburetors, proceed as follows: a. Allow engine to run for one minute. b. If idle RPM is not as specified, turn idle speed screw to obtain correct RPM. 11. On all models, turn off engine, connect vacuum lines and remove tachometer. Remove jumper wire and connect oxygen sensor electrical connector, if equipped. After step 11 has been completed, idle speed may change slightly. This condition is normal and engine speed should not be readjusted. Fast Idle Adjustment 1. Disconnect and plug vacuum hose at EGR valve, ESA computer and distributor, if equipped. 2. On models equipped with carburetor ground switch, connect jumper wire between switch and ground. 3. On models not equipped with Spark Control Computer (SCC), disconnect and plug vacuum hose from carburetor at heated air temperature sensor. 4. On all models, disconnect and plug control hose at canister. 5. Remove PCV valve from cylinder head cover and allow to draw underhood air. 6. Connect tachometer, then start engine and allow to reach normal operating temperature. 7. On models equipped with oxygen sensor feedback, disconnect electrical connector from oxygen sensor and ground connector, then allow engine to run for two minutes. 8. On models not equipped with oxygen sensor feedback, allow engine to run for one minute. 9. On all models, open throttle slightly and position fast idle adjusting screw on second highest step of fast idle cam. 10. Open choke fully, then adjust fast idle speed screw to obtain specified RPM. 11. Return to idle, then reposition adjusting screw on second highest step of fast idle cam to ensure correct RPM. Readjust if necessary. 12. Turn off engine, then connect vacuum hoses and remove tachometer. Remove jumper wire and connect oxygen sensor electrical connector, if equipped. After step 12 has been completed, idle speed may change slightly. This condition is normal and engine speed should not be readjusted. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package Technical Service Bulletin # 250485 Date: 850506 High Altitude Conversion Package Models 1985 Light Duty Domestic Trucks Subject High Altitude Conversion Packages & Adjustment for Improved Engine Performance Index EMISSIONS Date May 6, 1985 No.. 25-04-85 P-1522-C Packages are now available to accommodate a customer who wishes to convert his 1985 low altitude vehicle for improved high altitude (over 4,000 feet above sea level) engine performance. Vehicles with the low altitude package transferred to service in high altitude areas may exhibit undesirable driveability. However, the installation of a high altitude conversion package is voluntary and at the customer's expense. The high altitude field conversion packages and procedures outlined below have been authorized on the following 1985 non-altitude equipped engine families in service at altitudes above 4,000 feet above sea level. CONVERSION INSTRUCTIONS Sea Level to Altitude FIGURE 1 - Vehicle Emission Control Information Label IMPORTANT: IN SOME OF THE CONVERSION PROCEDURES YOU WILL BE REQUIRED TO INSTALL A NEW VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL PN 4275084. THIS LABEL HAS TWO AREAS THAT ARE IMPACT IMPRINTABLE WITH A TYPEWRITER (SEE FIGURE 1). If you are required to readjust timing, curb idle speed, or fast idle speed to a specification different than the original VECI label specification, then just type in the new specification after the subject operation. If you are asked to refer to the original VECI label specifications, type in on the right hand side of the label "Refer to Original VECI Label." Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2317 In every case where this label is used, type in after - AUTHORITY OF Technical Service Bulletin #25-04-85, and your dealer code below. Label PN 4275084 is available from Parts Supply. FIGURE 2 - Vehicle Emission Control Information Label The engine family chart below will help identify the appropriate parts to be installed by recording body style and engine family from the original VECI label. This chart cross references the EPA engine family with the engine application used in the accompanying instructions (refer to Figure 2). EPA Engine Family Engine Application (Found on VECI Label) 2.2L-2V Federal FCR2.2T2AAB6 2.2L-2V 50 States FCR2.2T2HBM9 2.6L-2V Federal FCR2.6T2AAB8 3.7L-1V Federal FCR3.7T1BBA0 5.2L-2V 50 States FCR5.2T2HBN1 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2318 5.2L-2V Federal FCR5.2T2BBF6 5.9L-4V Federal FCR5.9T4BBF1 POLICY: Information only 1985 2.2L-2V Light Duty Trucks All Models With Federal Emissions Package (49 States) Dodge Ram Van, Dodge Caravan, Plymouth Voy Consisting of: 1 - #211 Primary Main Jet PN 4293797 1 - #215 Secondary Main Jet PN 4240006 1 - #180 Primary High Speed Bleed PN 4342920 1 - #210 Secondary High Speed Bleed PN 4342921 1 - Carburetor Air Horn Gasket PN 4293846 INSTRUCTIONS FIGURE 1. Holley 5220 Primary Main Metering Jet #211 FIGURE 2. Holley 5220 Secondary Main Metering Jet #223 - Remove carburetor air horn. - Remove primary and secondary main metering jets. Refer to Figures 1 and 2. - Install #211 primary main metering jet PN 4293797. - Install #215 secondary main metering jet PN 4240006. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2319 FIGURE 3. Holley 5220 Primary High Speed Bleed #180 FIGURE 4. Holley 5220 Secondary High Speed Bleed #210 - Remove primary and secondary high speed bleeds. Refer to Figures 3 and 4. - Install #180 primary high speed bleed PN 4342920. - Install #210 secondary high speed bleed PN 4342921. FIGURE 5. Holley 5220 Power Valve Location - Turn power valve (Figure 5) two full turns counterclockwise (lean). - Reinstall air horn with new air horn gasket PN 4293846. Start engine and check for leaks. - Warm up engine and set idle speed to that specified on the VECI label. - Type in changes made on Emission Update Label PN 4275084 and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2320 1985 2.2L-2V Light Duty Truck Dodge Ram Van, Dodge Caravan & Plymouth Voyager Only Equipped With "50 States" Emission Package Consisting of: 1 - Carburetor (manual or automatic PN 4342891 transmission) Also order conversion hardware package. 1 - Hardware Package PN 4342950 Consisting of: 1 - Carburetor Base Gasket PN 4095975 1 - H.A.C. PN 4306202 1 - Hose Routing Diagram NPN 1 - Mounting Bracket (H.A.C.) PN 4105199 1 - H.A.C. Hose Harness NPN 3 - Mounting Screws NPN INSTRUCTIONS - Remove carburetor per instructions in appropriate engine performance/electrical shop manual. - Install new carburetor with new base gasket. FIGURE 6 - High Altitude Compensator Mounting - Install altitude compensator with bracket (Figure 6). - Install altitude compensator vacuum hose harness, route as shown in hose routing diagram (Figure 6). - Warm up engine. - Set engine idle speed to specified VECI label specification. - Set high fast idle on Step 3 (lowest) to specification. - Double check hose routing and installation of fuel lines. - Type in changes made on the Emission Update Label PN 4275084 and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2321 1985 2.6L-2V Light Duty Truck All Models With Federal Emissions Package (49 States) Consisting of: 1 - Carburetor Jet Kit PN MD088294 containing: #110 Primary Main Jet #175 Secondary Main Jet #100 Primary Air Bleed Jet #120 Secondary Air Bleed Jet 1 - Float Chamber Cover Gasket PN MD608639 1 - Choke Cover Screw Kit PN MD606977 1 - Carburetor Flange Gasket PN MD025344 INSTRUCTIONS - Remove carburetor from engine and take off air horn per instructions in appropriate service manual. FIGURE 7 - Mikuni Jet Locations - Remove primary and secondary main jets as shown in Figure 7. - Install #110 primary main jet and #175 secondary main jet in the primary and secondary pedestals. - Reinstall air horn on carburetor using new air horn gasket PN MD608639 and choke cover screw kit PN MD606977. FIGURE 8 - Mikuni Air Bleed Jet Locations - Remove primary and secondary air bleed jets shown in Figure 8. - Prepare carburetor for propane idle set by drilling out concealment plug. - Install #120 secondary air bleed jet and #100 primary air bleed jet. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2322 - Reinstall carburetor on engine using a new carburetor flange gasket, PN MD025344. - Remove vacuum controlled orificed tank vapor valve (VCOTV) and the vacuum/line(s) to the valve. - Remove the 3/16" tank vent line from the vapor canister and replace with 24" of 3/16" tank vent line and route directly to steel tank vent tube. - Remove the manifold vacuum line from the manifold vacuum tee (originally to the VCOTV) and cap the tee. - Remove the EGR delay valve at the corresponding EGR and carburetor ports and replace with 8" of bulk 3/16" vacuum line from stock. - Start engine and warm up to operating temperature. - Set idle rpm (curb) to 850 rpm and propane enriched rpm to 950 rpm. - Set throttle kicker rpm to 1050 rpm. FIGURE 9 - Authorized Modifications Label - Type in changes made on Authorized Modification Label, PN 4275086 (Figure 9), and affix to engine compartment next to VECI label. 1985 3.7L-1V Light Duty Trucks All Models With Federal Emission Package (49 States) Consisting of: 1 - #611 Main Metering Jet PN 3837520 1 - Carburetor Air Horn Gasket PN 4267140 INSTRUCTIONS - Remove carburetor. - Remove air horn from carburetor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2323 FIGURE 10 - Main Metering Jet Location - Remove existing main metering jet (Figure 10). - Install #611 main metering jet PN 3837520. - Reinstall air horn with new air horn gasket PN 4267140. - Drill out concealment plug and prepare carburetor for propane idle set. - Per instructions in appropriate service manual, perform a propane idle set. Reset the propane/curb idle speeds to 775/750 for manuals and 800/775 for automatics. - Reset HFI to 1600 on Step 2. - Reset choke vacuum kick to 0.120". - Reset idle solenoid speed to 850 rpm (manual transmission) or 875 (automatic transmission). - Type in changes made on Emission Update Label and affix in engine compartment next to VECI label. 1985 5.2L-2V Light Duty Trucks All Models With "50 States" Emissions Packages Consisting of: 1 - Carburetor PN 4306453 1 - EGR Valve PN 4094891 1 - EGR Valve Gasket PN 4287938 1 - Carburetor Gasket PN 4095970 INSTRUCTIONS Using procedures as outlined in the appropriate service manual, perform the following: - Remove existing carburetor. - Install replacement carburetor PN 4306453 and gasket. - Remove EGR valve and scrape off old gasket material. - Install replacement EGR valve PN 4094891 and new gasket PN 4287938. - Start engine and check for leaks. - Check and reset if necessary, curb idle, fast idle to VECI label specifications. - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2324 1985 5.2L-2V Light Duty Trucks All Models With Federal Emissions Package (49 States) Consisting of: 2 - Main Metering Jet #147 PN 4271983 1 - EGR Valve PN 4287678 1 - EGR Valve Gasket PN 4287938 1 - Carburetor Base Gasket PN 4095970 INSTRUCTIONS Per instructions in appropriate service manual, perform the following: - Remove carburetor from engine. - Remove air horn from carburetor. FIGURE 11 - Holley 2280 Main Metering Jets - Remove existing main metering jet (Figure 11). - Install main metering jets provided, PN 4271983. - Adjust vacuum kick to 0.150". - Adjust mechanical unloader to 0.280". - Remove EGR valve and scrape off old gasket material. - Install new EGR valve PN 4287678 with new gasket PN 4287938. - Start engine, check for leaks. - Prepare carburetor for propane idle set and reinstall on engine using gasket PN 4095970. - Start engine and check for leaks. - Perform propane idle adjustment to 700 rpm (curb idle) and 770 rpm (propane enriched idle). - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. 5.9L-4V Light Duty Trucks All Automatic Models With Federal Emissions Package Consisting of: 1 - Carburetor PN 4342807 1 - EGR Valve PN 4287659 1 - Carburetor Base Gasket PN 3698365 1 - EGR Valve Gasket PN 4287938 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2325 INSTRUCTIONS - Remove existing carburetor. - Install new carburetor PN 4342807 along with new carburetor base gasket PN 3698365. - Raise the rear wheels of the vehicle with the transmission in neutral. Rotate the rear wheels through one revolution and determine the axle ratio. - If the vehicle has a 3.55 or 4.10 axle, replace EGR valve with PN 4287659 and gasket PN 4287938. - Start engine and check for leaks. - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. 5.9L-4V Light Duty Trucks All Manual Models With Federal Emission Package Consisting of: 1 - Carburetor PN 4342807 1 - Carburetor Base Gasket PN 3698365 INSTRUCTIONS - Remove original carburetor. - Install replacement carburetor PN 4342807 using new base gasket PN 3698365. - Start engine and check for leaks. - Type in changes made on Emission Update Label PN 4275084 and affix to engine compartment next to original VECI label. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2326 Air/Fuel Mixture: Technical Service Bulletins Propane Idle Adjustment - Determination Guidelines Models 1985 Model Year Vehicles Subject Guidelines For Determining the Use of Idle Mixture Adjustment Index FUEL Date 10/1/84 No.. 14-46-84 P-4283C This bulletin should serve as a guideline to help determine when a propane or "CO" method idle set is to be performed. The propane or "CO" method idle mixture adjustment should only be performed if it is determined necessary by the propane or "CO" method idle check in the respective year Driveability Test Procedure books or service manual. More specifically, propane or "CO" method idle mixture adjustment should only be used if an idle "problem" still exists after normal diagnosis has revealed no other faulty condition such as incorrect idle speed, incorrect basic ignition timing, faulty hose, or wire connections, etc. It is also important to make sure the EFC/ESA combustion computer system is operating properly. Adjustment of the idle mixture should also be performed after a major carburetor overhaul. A guideline of conditions for determining whether a propane or "CO" method idle set is needed is attached. The conditions listed below are affected by idle mixture adjustment: ^ Rough Idle Warm ^ Breakaway Sag-Light Throttle Tip In ^ Decel Die Out ^ After a Major Carburetor Overhaul The conditions listed below are not affected by idle mixture adjustment: ^ Spark Knock ^ Poor Fuel Economy ^ Road Load Surge ^ Decel Bucking ^ Long Cold Crank ^ Cold Start Die Out Time ^ After-Run (dieseling) ^ Lack of Power on ^ Cold Rough Idle Acceleration POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Adjustments > Idle Mixture and Speed Adjustments Air/Fuel Mixture: Adjustments Idle Mixture and Speed Adjustments 1981-86: Disconnect and plug canister control and EGR vacuum hoses. Remove PCV valve from grommet and allow it to draw underhood air. With ESC, ground carb switch and disconnect Oxygen sensor. 1981-82: Set idle speed screw to specification. Set cam to specified step. Set fast idle. 1983-88, 6 & 8 cyl. models with solenoids.: Turn A/C on, set blower to low, disconnect compressor clutch wire. Without A/C, apply battery voltage to solenoid. Adjust speed-up solenoid by removing adjusting screw and spring and inserting a one-eighth inch allen wrench into socket and turning. Set idle speed by adjusting screw on carb body. 1987-88 4cyl.: Energize radiator fan with a jumper wire. Remove PCV valve from grommet and disconnect vacuum kicker solenoid electrical lead. Disconnect oxygen sensor test connector on left fender shield. Adjust idle speed screw on top of solenoid to specified idle speed. Place fast idle cam on specified step and adjust to specified value. Disconnect idle solenoid electrical lead and set base idle to specified value. Other models: Set idle speed by turning screw on carb body. Set cam to specified step and adjust fast idle to specification. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Adjustments > Idle Mixture and Speed Adjustments > Page 2329 Air/Fuel Mixture: Adjustments Idle Mixture (Propane Method) Fig. 1 Propane enrichment specification chart 1985 HOLLEY 6280 CARBURETOR This procedure should only be used after normal diagnosis has revealed no other faults, or if carburetor has been overhauled. Idle mixture adjustment requires artificial propane enrichment. A propane enrichment tool, C-4464 or equivalent, must be used to adjust idle mixture. Before proceeding, make sure that propane cylinder is adequately filled to ensure correct propane flow. 1. Remove concealment plug cap from mixture adjusting screw. Refer to appropriate carburetor section. 2. Set parking brake and place transmission in Neutral position. 3. Turn off all lights and accessories, then connect tachometer. 4. Start engine and allow to reach normal operating temperature, then turn off engine. 5. Disconnect and plug the vacuum hose at the EGR valve and ESA computer. 6. Disconnect and plug canister purge hose at canister. 7. Disconnect carburetor ground switch and ensure switch is not grounded. 8. Disconnect and ground oxygen sensor electrical connector. 9. start engine and allow to run for at least four minutes. 10. Disconnect vacuum supply hose from choke diaphragm at the carburetor, then install propane hose in its place. 11. Remove PCV valve from cylinder head and allow to draw in underhood air. Ensure that propane cylinder remains upright during procedure. 12. Open main propane valve fully. Slowly open propane metering valve until maximum idle RPM is obtained. Too much propane will cause engine speed to drop. Adjust metering valve to obtain maximum idle RPM. 13. With propane flowing, adjust idle speed to specified enriched RPM, Fig. 1, by turning idle speed screw. 14. Adjust metering valve to obtain maximum RPM. If there has been a change in maximum RPM, readjust idle speed screw to specified enriched RPM. 15. Turn off main propane valve and allow engine speed to stabilize. 16. Adjust mixture screws to obtain smoothest idle at specified curb idle RPM, allowing time between adjustments for engine speed to stabilize. 17. Turn on main propane valve and adjust metering valve to obtain maximum engine RPM. If maximum engine speed differs by more than 25 RPM from specified enriched RPM, repeat steps 12 through 17. 18. When adjustment is correct, turn off both propane valves, stop engine and remove tool. 19. Install new concealment plug, then connect oxygen sensor electrical connector. 20. Connect vacuum line at ESA, then perform ``Curb Idle Speed, Adjust'' and ``Fast Idle Speed, Adjust'' procedures. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Altitude Compensator > Component Information > Technical Service Bulletins > High Altitude Conversion Package Technical Service Bulletin # 250485 Date: 850506 High Altitude Conversion Package Models 1985 Light Duty Domestic Trucks Subject High Altitude Conversion Packages & Adjustment for Improved Engine Performance Index EMISSIONS Date May 6, 1985 No.. 25-04-85 P-1522-C Packages are now available to accommodate a customer who wishes to convert his 1985 low altitude vehicle for improved high altitude (over 4,000 feet above sea level) engine performance. Vehicles with the low altitude package transferred to service in high altitude areas may exhibit undesirable driveability. However, the installation of a high altitude conversion package is voluntary and at the customer's expense. The high altitude field conversion packages and procedures outlined below have been authorized on the following 1985 non-altitude equipped engine families in service at altitudes above 4,000 feet above sea level. CONVERSION INSTRUCTIONS Sea Level to Altitude FIGURE 1 - Vehicle Emission Control Information Label IMPORTANT: IN SOME OF THE CONVERSION PROCEDURES YOU WILL BE REQUIRED TO INSTALL A NEW VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL PN 4275084. THIS LABEL HAS TWO AREAS THAT ARE IMPACT IMPRINTABLE WITH A TYPEWRITER (SEE FIGURE 1). If you are required to readjust timing, curb idle speed, or fast idle speed to a specification different than the original VECI label specification, then just type in the new specification after the subject operation. If you are asked to refer to the original VECI label specifications, type in on the right hand side of the label "Refer to Original VECI Label." Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Altitude Compensator > Component Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2334 In every case where this label is used, type in after - AUTHORITY OF Technical Service Bulletin #25-04-85, and your dealer code below. Label PN 4275084 is available from Parts Supply. FIGURE 2 - Vehicle Emission Control Information Label The engine family chart below will help identify the appropriate parts to be installed by recording body style and engine family from the original VECI label. This chart cross references the EPA engine family with the engine application used in the accompanying instructions (refer to Figure 2). EPA Engine Family Engine Application (Found on VECI Label) 2.2L-2V Federal FCR2.2T2AAB6 2.2L-2V 50 States FCR2.2T2HBM9 2.6L-2V Federal FCR2.6T2AAB8 3.7L-1V Federal FCR3.7T1BBA0 5.2L-2V 50 States FCR5.2T2HBN1 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Altitude Compensator > Component Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2335 5.2L-2V Federal FCR5.2T2BBF6 5.9L-4V Federal FCR5.9T4BBF1 POLICY: Information only 1985 2.2L-2V Light Duty Trucks All Models With Federal Emissions Package (49 States) Dodge Ram Van, Dodge Caravan, Plymouth Voy Consisting of: 1 - #211 Primary Main Jet PN 4293797 1 - #215 Secondary Main Jet PN 4240006 1 - #180 Primary High Speed Bleed PN 4342920 1 - #210 Secondary High Speed Bleed PN 4342921 1 - Carburetor Air Horn Gasket PN 4293846 INSTRUCTIONS FIGURE 1. Holley 5220 Primary Main Metering Jet #211 FIGURE 2. Holley 5220 Secondary Main Metering Jet #223 - Remove carburetor air horn. - Remove primary and secondary main metering jets. Refer to Figures 1 and 2. - Install #211 primary main metering jet PN 4293797. - Install #215 secondary main metering jet PN 4240006. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Altitude Compensator > Component Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2336 FIGURE 3. Holley 5220 Primary High Speed Bleed #180 FIGURE 4. Holley 5220 Secondary High Speed Bleed #210 - Remove primary and secondary high speed bleeds. Refer to Figures 3 and 4. - Install #180 primary high speed bleed PN 4342920. - Install #210 secondary high speed bleed PN 4342921. FIGURE 5. Holley 5220 Power Valve Location - Turn power valve (Figure 5) two full turns counterclockwise (lean). - Reinstall air horn with new air horn gasket PN 4293846. Start engine and check for leaks. - Warm up engine and set idle speed to that specified on the VECI label. - Type in changes made on Emission Update Label PN 4275084 and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Altitude Compensator > Component Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2337 1985 2.2L-2V Light Duty Truck Dodge Ram Van, Dodge Caravan & Plymouth Voyager Only Equipped With "50 States" Emission Package Consisting of: 1 - Carburetor (manual or automatic PN 4342891 transmission) Also order conversion hardware package. 1 - Hardware Package PN 4342950 Consisting of: 1 - Carburetor Base Gasket PN 4095975 1 - H.A.C. PN 4306202 1 - Hose Routing Diagram NPN 1 - Mounting Bracket (H.A.C.) PN 4105199 1 - H.A.C. Hose Harness NPN 3 - Mounting Screws NPN INSTRUCTIONS - Remove carburetor per instructions in appropriate engine performance/electrical shop manual. - Install new carburetor with new base gasket. FIGURE 6 - High Altitude Compensator Mounting - Install altitude compensator with bracket (Figure 6). - Install altitude compensator vacuum hose harness, route as shown in hose routing diagram (Figure 6). - Warm up engine. - Set engine idle speed to specified VECI label specification. - Set high fast idle on Step 3 (lowest) to specification. - Double check hose routing and installation of fuel lines. - Type in changes made on the Emission Update Label PN 4275084 and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Altitude Compensator > Component Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2338 1985 2.6L-2V Light Duty Truck All Models With Federal Emissions Package (49 States) Consisting of: 1 - Carburetor Jet Kit PN MD088294 containing: #110 Primary Main Jet #175 Secondary Main Jet #100 Primary Air Bleed Jet #120 Secondary Air Bleed Jet 1 - Float Chamber Cover Gasket PN MD608639 1 - Choke Cover Screw Kit PN MD606977 1 - Carburetor Flange Gasket PN MD025344 INSTRUCTIONS - Remove carburetor from engine and take off air horn per instructions in appropriate service manual. FIGURE 7 - Mikuni Jet Locations - Remove primary and secondary main jets as shown in Figure 7. - Install #110 primary main jet and #175 secondary main jet in the primary and secondary pedestals. - Reinstall air horn on carburetor using new air horn gasket PN MD608639 and choke cover screw kit PN MD606977. FIGURE 8 - Mikuni Air Bleed Jet Locations - Remove primary and secondary air bleed jets shown in Figure 8. - Prepare carburetor for propane idle set by drilling out concealment plug. - Install #120 secondary air bleed jet and #100 primary air bleed jet. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Altitude Compensator > Component Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2339 - Reinstall carburetor on engine using a new carburetor flange gasket, PN MD025344. - Remove vacuum controlled orificed tank vapor valve (VCOTV) and the vacuum/line(s) to the valve. - Remove the 3/16" tank vent line from the vapor canister and replace with 24" of 3/16" tank vent line and route directly to steel tank vent tube. - Remove the manifold vacuum line from the manifold vacuum tee (originally to the VCOTV) and cap the tee. - Remove the EGR delay valve at the corresponding EGR and carburetor ports and replace with 8" of bulk 3/16" vacuum line from stock. - Start engine and warm up to operating temperature. - Set idle rpm (curb) to 850 rpm and propane enriched rpm to 950 rpm. - Set throttle kicker rpm to 1050 rpm. FIGURE 9 - Authorized Modifications Label - Type in changes made on Authorized Modification Label, PN 4275086 (Figure 9), and affix to engine compartment next to VECI label. 1985 3.7L-1V Light Duty Trucks All Models With Federal Emission Package (49 States) Consisting of: 1 - #611 Main Metering Jet PN 3837520 1 - Carburetor Air Horn Gasket PN 4267140 INSTRUCTIONS - Remove carburetor. - Remove air horn from carburetor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Altitude Compensator > Component Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2340 FIGURE 10 - Main Metering Jet Location - Remove existing main metering jet (Figure 10). - Install #611 main metering jet PN 3837520. - Reinstall air horn with new air horn gasket PN 4267140. - Drill out concealment plug and prepare carburetor for propane idle set. - Per instructions in appropriate service manual, perform a propane idle set. Reset the propane/curb idle speeds to 775/750 for manuals and 800/775 for automatics. - Reset HFI to 1600 on Step 2. - Reset choke vacuum kick to 0.120". - Reset idle solenoid speed to 850 rpm (manual transmission) or 875 (automatic transmission). - Type in changes made on Emission Update Label and affix in engine compartment next to VECI label. 1985 5.2L-2V Light Duty Trucks All Models With "50 States" Emissions Packages Consisting of: 1 - Carburetor PN 4306453 1 - EGR Valve PN 4094891 1 - EGR Valve Gasket PN 4287938 1 - Carburetor Gasket PN 4095970 INSTRUCTIONS Using procedures as outlined in the appropriate service manual, perform the following: - Remove existing carburetor. - Install replacement carburetor PN 4306453 and gasket. - Remove EGR valve and scrape off old gasket material. - Install replacement EGR valve PN 4094891 and new gasket PN 4287938. - Start engine and check for leaks. - Check and reset if necessary, curb idle, fast idle to VECI label specifications. - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Altitude Compensator > Component Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2341 1985 5.2L-2V Light Duty Trucks All Models With Federal Emissions Package (49 States) Consisting of: 2 - Main Metering Jet #147 PN 4271983 1 - EGR Valve PN 4287678 1 - EGR Valve Gasket PN 4287938 1 - Carburetor Base Gasket PN 4095970 INSTRUCTIONS Per instructions in appropriate service manual, perform the following: - Remove carburetor from engine. - Remove air horn from carburetor. FIGURE 11 - Holley 2280 Main Metering Jets - Remove existing main metering jet (Figure 11). - Install main metering jets provided, PN 4271983. - Adjust vacuum kick to 0.150". - Adjust mechanical unloader to 0.280". - Remove EGR valve and scrape off old gasket material. - Install new EGR valve PN 4287678 with new gasket PN 4287938. - Start engine, check for leaks. - Prepare carburetor for propane idle set and reinstall on engine using gasket PN 4095970. - Start engine and check for leaks. - Perform propane idle adjustment to 700 rpm (curb idle) and 770 rpm (propane enriched idle). - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. 5.9L-4V Light Duty Trucks All Automatic Models With Federal Emissions Package Consisting of: 1 - Carburetor PN 4342807 1 - EGR Valve PN 4287659 1 - Carburetor Base Gasket PN 3698365 1 - EGR Valve Gasket PN 4287938 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Altitude Compensator > Component Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2342 INSTRUCTIONS - Remove existing carburetor. - Install new carburetor PN 4342807 along with new carburetor base gasket PN 3698365. - Raise the rear wheels of the vehicle with the transmission in neutral. Rotate the rear wheels through one revolution and determine the axle ratio. - If the vehicle has a 3.55 or 4.10 axle, replace EGR valve with PN 4287659 and gasket PN 4287938. - Start engine and check for leaks. - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. 5.9L-4V Light Duty Trucks All Manual Models With Federal Emission Package Consisting of: 1 - Carburetor PN 4342807 1 - Carburetor Base Gasket PN 3698365 INSTRUCTIONS - Remove original carburetor. - Install replacement carburetor PN 4342807 using new base gasket PN 3698365. - Start engine and check for leaks. - Type in changes made on Emission Update Label PN 4275084 and affix to engine compartment next to original VECI label. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions Technical Service Bulletin # 140487 Date: 870504 Carburetor Adjustments - Manual Revisions Models 1984-1987 "D" Truck & "B" Van 1987 "N" Truck 1985-1987 "M" Body Subject Accelerator Pump & Bowl Vent - Adjustment - Service Manual Revisions Index FUEL Date May 4, 1987 No. 14-04-87 (C1-14) This bulletin is issued to revise the accelerator pump and bowl vent adjustment procedures. Corrections to the service manual are listed below. Use the charts provided to make the necessary changes and/or replace the pages as required. On the service manual publications listed below, replace the entire bowl vent valve adjustment procedure, including the picture, with the procedure and picture provided. NOTE: THE NEW PROCEDURE IS SHOWN IN DUPLICATE TO REDUCE PRINTING. USE ONLY 1/2 OF THE ATTACHMENT PER PAGE. Manual Publication No. Page No. 1984 RWD Van 81-370-4007 14-61 Add Item 1984 RWD Truck 81-370-4008 14-61 Add Item 1985 RWD Van 81-370-5007 14-60, Item 7 1985 RWD Truck 81-370-5008 14-60, Item 7 1986 RWD Van 81-370-6007 14-51, Item 7 1986 RWD Truck 81-370-6008 14-50, Item 7 1987 RWD Van 81-370-7007 14-58, Item 8 1987 RWD Truck 81-370-7008 14-60, Item 8 1987 RWD Car 81-270-7001 14-21, Item 8 In the following three service manuals it will be necessary to correct the accelerator pump adjustment specification. Change the .135" +/- .010" to .180" +/- .010" as listed below. 1. 1987 Rear Wheel Drive Car - Publication #81-270-7001, pages 14-17, Step 12 and page 14-20, Step 3. 2. 1987 Rear Wheel Drive Truck - Publication #81-370-7008 pages 14-56, Step 12 and page 14-60, Step 3. 3. 1987 Rear Wheel Drive Van - Publication #81-370-7007, pages 14-54, Step 12 and 14-58, Step 3. Using the following chart, replace the pages as indicated with the revised pages supplied. Service Manual Publication No. Revised Pages 1985 Rear Wheel Drive Car 81-270-5001 14-25 1986 Rear Wheel Drive Car 81-270-6001 14-16, 14-17, 14-20, 14-21 & 14-23 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2348 1986 Rear Wheel Drive Van 81-370-6007 14-46, 14-47, 14-50 & 14-54 1986 Rear Wheel Drive Truck 81-370-6008 14-45, 14-49 & 14-54 1987 Dakota 81-370-6010 14-32 1987 Dakota 81-370-7010 14-40 POLICY: Information only Publication #81-370-4007 TSB 14-04-87 May 4, 1987 Publication #81-370-4007 Page 14-61 BOWL VENT VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate and vent valve lever spring. CAUTION: Do not dislodge or misplace vent valve lever retainer/pivot pin. (2) With the throttle in the curb idle position, press firmly down on the vent valve lever where the spring seats; with another finger of the same hand, simultaneously press down on the vent valve tang until the vent valve is lightly seated (closed). CAUTION: If the carburetor is not on the engine, it must be on a raised fixture so as not to change the curb idle throttle plate position. (3) Using the other hand, measure the resulting gap between the contact surfaces of the vent valve lever and the vent valve tang with an appropriate gauge. (4) Adjust by bending the end of the vent valve lever up or down until the specified gap (.030") is set. (5) Install vent valve lever spring and bowl vent cover plate. NOTE: THE BOWL VENT VALVE AJUSTMENT MUST BE RESET IF THE ACCELERATOR PUMP ADJUSTMENT IS CHANGED. Publication #81-370-4008 TSB 14-04-87 May 4, 1987 Publication #81-370-4008 Page 14-61 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2349 BOWL VENT VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate and vent valve lever spring. CAUTION: Do not dislodge or misplace vent valve lever retainer/pivot pin. (2) With the throttle in the curb idle position, press firmly down on the vent valve lever where the spring seats; with another finger of the same hand, simultaneously press down on the vent valve tang until the vent valve is lightly seated (closed). CAUTION: If the carburetor is not on the engine, it must be on a raised fixture so as not to change the curb idle throttle plate position. (3) Using the other hand, measure the resulting gap between the contact surfaces of the vent valve lever and the vent valve tang with an appropriate gauge. (4) Adjust by bending the end of the vent valve lever up or down until the specified gap (.030") is set. (5) Install vent valve lever spring and bowl vent cover plate. NOTE: THE BOWL VENT VALVE ADJUSTMENT MUST BE RESET IF THE ACCELERATOR PUMP ADJUSTMENT IS CHANGED. Publication #81-370-5007 TSB 14-04-87 May 4, 1987 Publication #81-370-5007 Page 14-60 7. BOWL VENT VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate and vent valve lever spring. CAUTION: Do not dislodge or misplace vent valve lever retainer/pivot pin. (2) With the throttle in the curb idle position, press firmly down on the vent valve lever where the spring seats; with another finger of the same hand, simultaneously press down on the vent valve tang until the vent valve is lightly seated (closed). CAUTION: If the carburetor is not on the engine, it must be on a raised fixture so as not to change. the curb idle throttle plate position. (3) Using the other hand, measure the resulting gap between the contact surfaces of the vent valve lever and the vent valve tang with an appropriate gauge. (4) Adjust by bending the end of the vent valve lever up or down until the specified gap (.030") is set. (5) Install vent valve lever spring and bowl vent cover plate. NOTE: THE BOWL VENT VALVE ADJUSTMENT MUST BE RESET IF THE ACCELERATOR PUMP ADJUSTMENT IS CHANGED. Publication #81-370-5008 TSB 14-04-87 May 4, 1987 Publication #81-370-5008 Page 14-60 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2350 7. BOWL VENT VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate and vent valve lever spring. CAUTION: Do not dislodge or misplace vent valve lever retainer/pivot pin. (2) With the throttle in the curb idle position, press firmly down on the vent valve lever where the spring seats; with another finger of the same hand, simultaneously press down on the vent valve tang until the vent valve is lightly seated (closed). CAUTION: If the carburetor is not on the engine, it must be on a raised fixture so as not to change the curb idle throttle plate position. (3) Using the other hand, measure the resulting gap between the contact surfaces of the vent valve lever and the vent valve tang with an appropriate gauge. (4) Adjust by bending the end of the vent valve lever up or down until the specified gap (.030") is set. (5) Install vent valve lever spring and bowl vent cover plate. NOTE: THE BOWL VENT VALVE ADJUSTMENT MUST BE RESET IF THE ACCELERATOR PUMP ADJUSTMENT IS CHANGED. Publication #81-370-6007 TSB 14-04-87 May 4, 1987 Publication #81-370-6007 Page 14-51 7. BOWL VENT VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate and vent valve lever spring. CAUTION: Do not dislodge or misplace vent valve lever retainer/pivot pin. (2) With the throttle in the curb idle position, press firmly down on the vent valve lever where the spring seats; with another finger of the same hand, simultaneously press down on the vent valve tang until the vent valve is lightly seated (closed). CAUTION: If the carburetor is not on the engine, it must be on a raised fixture so as not to change the curb idle throttle plate position. (3) Using the other hand, measure the resulting gap between the contact surfaces of the vent valve lever and the vent valve tang with an appropriate gauge. (4) Adjust by bending the end of the vent valve lever up or down until the specified gap (.030") is set. (5) Install vent valve lever spring and bowl vent cover plate. NOTE: THE BOWL VENT VALVE ADJUSTMENT MUST BE RESET IF THE ACCELERATOR PUMP ADJUSTMENT IS CHANGED. Publication #81-370-6008 TSB 14-04-87 May 4, 1987 Publication #81-370-6008 Page 14-50 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2351 7. BOWL VENT VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate and vent valve lever spring. CAUTION: Do not dislodge or misplace vent valve lever retainer/pivot pin. (2) With the throttle in the curb idle position, press firmly down on the vent valve lever where the spring seats; with another finger of the same hand, simultaneously press down on the vent valve tang until the vent valve is lightly seated (closed). CAUTION: If the carburetor is not on the engine, it must be on a raised fixture so as not to change the curb idle throttle plate position. (3) Using the other hand, measure the resulting gap between the contact surfaces of the vent valve lever and the vent valve tang with an appropriate gauge. (4) Adjust by bending the end of the vent valve lever up or down until the specified gap (.030") is set. (5) Install vent valve lever spring and bowl vent cover plate. NOTE: THE BOWL VENT VALVE ADJUSTMENT MUST BE RESET IF THE ACCELERATOR PUMP ADJUSTMENT IS CHANGED. Publication #81-370-7007 TSB 14-04-87 May 4, 1987 Publication #81-370-7007 Page 14-58 8. BOWL VENT VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate and vent valve lever spring. CAUTION: Do not dislodge or misplace vent valve lever retainer/pivot pin. (2) With the throttle in the curb idle position, press firmly down on the vent valve lever where the spring seats; with another finger of the same hand, simultaneously press down on the vent valve tang until the vent valve is lightly seated (closed). CAUTION: If the carburetor is not on the engine, it must be on a raised fixture so as not to change. the curb idle throttle plate position. (3) Using the other hand, measure the resulting gap between the contact surfaces of the vent valve lever and the vent valve tang with an appropriate gauge. (4) Adjust by bending the end of the vent valve lever up or down until the specified gap (.030") is set. (5) Install vent valve lever spring and bowl vent cover plate. NOTE: THE BOWL VENT VALVE ADJUSTMENT MUST BE RESET IF THE ACCELERATOR PUMP ADJUSTMENT IS CHANGED. Publication #81-370-7008 TSB 14-04-87 May 4, 1987 Publication #81-370-7008 Page 14-60 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2352 8. BOWL VENT VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate and vent valve lever spring. CAUTION: Do not dislodge or misplace vent valve lever retainer/pivot pin. (2) With the throttle in the curb idle position, press firmly down on the vent valve lever where the spring seats; with another finger of the same hand, simultaneously press down on the vent valve tang until the vent valve is lightly seated (closed). CAUTION: If the carburetor is not on the engine, it must be on a raised fixture so as not to change the curb idle throttle plate position. (3) Using the other hand, measure the resulting gap between the contact surfaces of the vent valve lever and the vent valve tang with an appropriate gauge. (4) Adjust by bending the end of the vent valve lever up or down until the specified gap (.030") is set. (5) Install vent valve lever spring and bowl vent cover plate. NOTE: THE BOWL VENT VALVE ADJUSTMENT MUST BE RESET IF THE ACCELERATOR PUMP ADJUSTMENT IS CHANGED. Publication #81-270-7001 TSB 14-04-87 May 4, 1987 Publication #81-270-7001 Page 14-21 8. BOWL VENT VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate and vent valve lever spring. CAUTION: Do not dislodge or misplace vent valve lever retainer/pivot pin. (2) With the throttle in the curb idle position, press firmly down on the vent valve lever where the spring seats; with another finger of the same hand, simultaneously press down on the vent valve tang until the vent valve is lightly seated (closed). CAUTION: If the carburetor is not on the engine, it must be on a raised fixture so as not to change, the curb idle throttle plate position. (3) Using the other hand, measure the resulting gap between the contact surfaces of the vent valve lever and the vent valve tang with an appropriate gauge. (4) Adjust by bending the end of the vent valve lever, up or down until the specified gap (.030") is set. (5) Install vent valve lever spring and bowl vent cover plate. NOTE: THE BOWL VENT VALVE ADJUSTMENT MUST BE RESET IF THE ACCELERATOR PUMP ADJUSTMENT IS CHANGED. Publication #81-270-5001 TSB 14-04-87 May 4, 1987 Publication #81-270-5001 (3) Return to idle then reposition the adjusting screw on to the second highest step of the fast idle cam to verify fast idle speed. Readjust if necessary. (4) Return to idle and turn the engine off. Unplug and reconnect the vacuum hoses at the EGR valve and canister. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2353 (5) Reinstall the air cleaner and unplug and reconnect the vacuum hose from the carburetor to the heated air temperature sensor on the air cleaner. Remove the tachometer and reinstall the PCV valve. Idle speeds with the engine in normal operating condition (everything connected) may vary from set speeds. DO NOT READJUST. 11. CONCEALMENT PLUG REMOVAL (1) Remove air cleaner. (2) Disconnect all hoses from front of carburetor base. (3) Center punch at a point 1/4 inch from end of mixture screw housing. (4) Drill through at punch mark with 3/6 inch drill bit. (5) Repeat operation on opposite side. (6) Pry out plugs and save for reuse. (7) Reinstall hoses and air cleaner. BOWL VENT VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate and vent valve lever spring. CAUTION: Do not dislodge or misplace vent valve lever retainer/pivot pin. (2) With the throttle in the curb idle position, press firmly down on the vent valve lever where the spring seats; with another finger of the same hand, simultaneously press down on the vent valve tang until the vent valve is lightly seated(closed). CAUTION: If the carburetor is not on the engine, it must be on a raised fixture so as not to change the curb idle throttle plate position. (3) Using the other hand, measure the resulting gap between the contact surfaces of the vent valve lever and the vent valve tang with an appropriate gauge. (4) Adjust by bending the end of the vent valve lever up or down until the specified gap (.030") is set. (5) Install vent valve lever spring and bowl vent cover plate. NOTE: THE BOWL VENT VALVE ADJUSTMENT MUST, BE RESET IF THE ACCELERATOR PUMP ADJUSTMENT IS CHANGED. Publication #81-270-6001 TSB 14-04-87 May 4, 1987 Publication #81-270-6001 filling the fuel bowl with clean fuel, using another accelerator pump plunger assembly. Hold the discharge check ball and weight down with a small brass rod and operate the pump plunger by hand. If the check ball and seat are leaking, no resistance will be experienced when operating the plunger (Fig. 16). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2354 If the valve is leaking, remove weight and stake the ball using a suitable drift punch. Exercise care when staking the ball to avoid damaging the bore containing the pump weight. After staking with the old ball, remove and replace with new ball from tuneup kit. Install weight and re-check for leaks. (4) Install new gaskets on venturi cluster, then install cluster in position in main body (Fig. 13). Install cluster screws and tighten securely. (5) Install main metering jets (Fig. 11). (6) Install vacuum and mechanical power valves (2280 models only) using Special Tool C-4231 (Fig. 12). Be careful not to damage power valve needles. CAUTION: Be sure the Power Valves are installed in their proper location, Mechanical Valve on choke side and Vacuum Valve on Throttle Lever Side. (7) A nitrophyl float can be checked for fuel absorption by lightly squeezing between fingers. If wetness appears on surface or float feels heavy (check with known good float), replace the float assembly. (8) Install hinge pin in float assembly. Insert hinge through slot in float baffle with tabs on baffle pointing downward. Position assembly in hinge pin cradle in carburetor main body (Fig. 10). (9) Place a new gasket on fuel inlet fitting and install assembly into main body, tighten securely to 180 inch pounds (20 N-m). Check float level. Refer to carburetor adjustments for adjusting procedure. (10) Install feedback solenoid on 6280 models. FIGURE 17 - SERVICING VACUUM POWER VALVE PISTON AND RETAINING RING Air Horn (1) Test freeness of choke mechanism in air horn. The choke shaft must float free to operate correctly. If choke sticks in bearing bores, or appears to be gummed from deposits in air horn, a thorough cleaning will be required. (2) Before installing the vacuum power valve assembly in bowl cover, be sure and remove all staking from the retainer cavity. Install the spring and piston in the vacuum cylinder, seat the retainer and stake lightly with suitable tool (Fig. 17). Compress piston to be sure no binding exists. If piston sticks or binds enough to hinder smooth operation, a new piston should be installed. FIGURE 18 - SERVICING MECHANICAL POWER VALVE PUSH ROD (3) Install mechanical power valve push rod spring, push rod and "E" clip retainer. Push plastic cap on to push rod (2280 models only) (Fig. 18). (4) Install accelerator pump plunger assembly through air horn and attach internal lever with C-link (2280 models only). On 6280 models, install new accelerator pump cup. (5) Place a new gasket on air horn. Lower air horn straight down on main body; guiding accelerator pump plunger into its cylinder. Do not cut lip of Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2355 plunger on sharp edge of cylinder. Install attaching screws and tighten to 25 inch pounds from center out. TSB 14-04-87 May 4, 1987 Publication #81-270-6001 (6) Install accelerator pump arm, internal pump lever and pump operating shaft. On 2280 C link and internal pump lever must be attached to accelerator pump shaft. Install "E" clip (Fig. 5). (7) To install fast idle connector link, engage plain end in slot of fast idle cam (from inside). Engage other end of rod in choke lever. With choke valve wide open, slide lever over choke shaft; (aligning flats). Install attaching lockwasher and nut. Tighten securely (Fig. 3). (8) Install accelerator pump link in No. 1 hole closest to Air Horn and retain with cotter pin on throttle lever end. (9) Engage choke diaphragm link in slot in choke lever. Install choke diaphragm assembly and secure with attaching screws (Fig. 2). Reinstall Vacuum Hose to Main Body. (10) Install bowl vent assembly (Fig. 1). (11) With pump links and levers installed, adjust the throttle blades to the closed position by backing out the idle speed screw. (12) Set the distance from the top of pump lever to the top of bowl vent cover surface to .050 +/.005 for 2280 models or .180 +/- .010 for 6280 models by bending the pump link. Check that wide open throttle can be reached without binding. (13) Install gasket and bowl vent cover plate. (14) Install Idle Stop Solenoid. (15) Install air cleaner bolt and retainer assembly. (16) Remove carburetor from repair stand. Choke Vacuum Kick The choke diaphragm adjustment controls the fuel delivery while the engine is running. It positions the choke valve within the air horn by action of the linkage between the choke shaft and the diaphragm. The diaphragm must be actuated to measure the vacuum kick adjustment. Vacuum can be supplied by an auxiliary vacuum source. Choke Unloader (Wide Open Kick) The choke unloader is a mechanical device to partially open the choke valve at wide open throttle. It is used to eliminate choke enrichment during cranking of an engine. Engines which have been flooded or stalled by excessive choke enrichment can be cleared by use of the unloader. Refer to carburetor adjustments for adjusting procedure. Fast Idle Speed Fast idle engine speed is used to overcome cold engine friction, stalls after cold starts and stalls because of carburetor icing. Refer to carburetor adjustments for procedure. Fast Idle Cam Position This adjustment is used to provide cam stop speeds at proper times during engine warmup. TSB 14-04-87 May 4, 1987 Publication #81-270-6001 5. MECHANICAL POWER VALVE ADJUSTMENT (2280 MODELS ONLY) (1) Remove bowl vent cover plate. (2) Hold throttle in wide open position. (3) Insert 5/64" Allen wrench in mechanical power valve adjustment screw. (4) Push screw down and release to determine if clearance exists. Turn screw clockwise until clearance is zero. (5) Adjust by turning screw counter clockwise one turn. (6) Install bowl vent gasket and cover plate. IF ACCELERATOR PUMP ADJUSTMENT IS CHANGED, THIS ADJUSTMENT MUST BE RESET. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2356 6. ACCELERATOR PUMP STROKE MEASUREMENT 6280 MODELS (1) Remove bowl vent cover plate and gasket. (2) With pump links and levers installed, adjust the throttle blades to the closed position by backing out the idle speed screw. (3) Set the distance from the top of pump lever to the top of bowl vent cover surface to .180 +/.010" by bending the pump link. Check that wide open throttle can be reached without binding. (4) Install gasket and bowl vent cover plate. (5) Reset Idle Speed. TSB 14-04-87 May 4, 1987 Publication #81-270-6001 7. ACCELERATOR PUMP STROKE MEASUREMENT 2280 MODELS (1) Remove bowl vent cover plate and vent valve lever and spring. Caution. Do not dislodge or lose vent valve lever retainer. (2) With pump link in No. 1 inner hole and levers installed, adjust the throttle blades to the closed position by backing out the idle speed screw. (3) Set the distance from the top of pump lever to the top of bowl vent cover surface to .050" +/.005" by bending the pump link. Check that wide open throttle can be reached without binding. (4) Install vent valve lever and spring and gasket and bowl vent cover plate. (5) Reset Idle Speed. NOTE: IF THIS ADJUSTMENT IS CHANGED, BOTH THE BOWL VENT AND THE MECHANICAL POWER VALVE ADJUSTMENTS MUST BE RESET. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2357 8. IDLE RPM ADJUSTMENT (2280 MODELS) Before checking or adjusting any idle speed, check ignition timing and adjust if necessary using the procedure shown in Group 8 Electrical. Disconnect and plug the vacuum hose at the EGR valve. Also disconnect and plug the vacuum hose from the carburetor at the heated air temperature sensor. Remove the air cleaner and disconnect and plug the 3/16 inch diameter control hose at the canister. Remove the PCV valve from the cylinder head cover and allow the valve to draw underhood air. Disconnect and plug vacuum hose at ESA module. Install tachometer. Start and run engine until normal operating temperature is reached. RPM Chrysler No. Vendor No. Refer to VECI Label 4288581 R-40245A On a new vehicle (under 300 miles/500 km), reduce RPM settings by 75 RPM. (1) Allow the engine to run for one minute for the engine speed to stabilize. (2) If the engine rpm is not correct, turn the idle speed screw to obtain the correct idle rpm. (3) Turn off engine. Unplug and reconnect vacuum hoses at EGR valve, canister, and ESA Module. (4) Reinstall air cleaner and unplug and reconnect vacuum hose from carburetor to heated air temperature sensor on air cleaner. Remove tachometer and reinstall PCV valve. Idle speeds with the engine in normal operating condition (all hoses and wires connected) may vary from set speeds. DO NOT READJUST. TSB 14-04-87 May 4, 1987 Publication #81-270-6001 (6) Return to idle and turn the engine off. Unplug and reconnect the vacuum hoses at the EGR valve and canister. Remove jumper wire. (7) Model 6280 only-separate carburetor electrical connector from engine wire harness. Reinstall the green and blue wires in their correct positions. Reconnect to the engine wire harness. (8) Reinstall the air cleaner and unplug and reconnect the vacuum hose from the carburetor to the heated air temperature sensor on the air cleaner. Remove the tachometer and reinstall the PCV valve. Idle speeds with the engine in normal operating condition (everything connected) may vary from set speeds. DO NOT READJUST. 11. CONCEALMENT PLUG REMOVAL Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2358 (1) Remove air cleaner. (2) Disconnect all hoses from front of carburetor base. (3) Center punch at a point 1/4 inch from end of mixture screw housing. (4) Drill through at punch mark with 3/16 inch drill bit. (5) Repeat operation on opposite side. (6) Pry out plugs and save for reuse. (7) Reinstall hoses and air cleaner. BOWL VENT VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate and vent valve lever spring. CAUTION: Do not dislodge or misplace vent valve lever retainer/pivot pin. (2) With the throttle in the curb idle position, press firmly down on the vent valve lever where the spring seats; with another finger of the same hand, simultaneously press down on the vent valve tang until the vent valve is lightly seated (closed). CAUTION: If the carburetor is not on the engine, it must be on a raised fixture so as not to change, the curb idle throttle plate position. (3) Using the other hand, measure the resulting gap between the contact surfaces of the vent valve lever and the vent valve tang with an appropriate gauge. (4) Adjust by bending the end of the vent valve lever up or down until the specified gap (.030") is set. (5) Install vent valve lever spring and bowl vent cover plate. NOTE: THE BOWL VENT VALVE ADJUSTMENT MUST BE RESET IF THE ACCELERATOR PUMP ADJUSTMENT IS CHANGED. Publication #81-370-6007 FIGURE 16 - SERVICING VACUUM POWER VALVE PISTON AND RETAINING RING TSB 14-04-87 May 4, 1987 Publication #81-370-6007 tween fingers. If wetness appears on surface or float feels heavy (check with known good float), replace the float assembly. (8) Place a new gasket on fuel inlet fitting and install assembly into main body, tighten securely. Check float level. Refer to carburetor adjustments for adjusting procedure. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2359 FIGURE 17 - SERVICING MECHANICAL POWER VALVE PUSH ROD Air Horn (1) Test freeness of choke mechanism in air horn. The choke shaft must float free to operate correctly. If choke sticks in bearing bores, or appears to be gummed from deposits in air horn, a thorough cleaning will be required. (2) Install vacuum power piston spring and piston in its cylinder, Place retaining ring over piston stem and carefully seat in place (Fig. 7). Compress piston to be sure no binding exists. If piston sticks or binds enough to hinder smooth operation, a new piston should be installed. (3) Install mechanical power valve push rod spring, push rod and "E" clip retainer. Push plastic cap on to push rod (2280 models only) (Fig. 17). (4) Install accelerator pump plunger assembly through air horn and attach internal lever with C-link (2280 models only). On 6280 models, install new accelerator pump cup. (5) Place a new gasket on air horn. Lower air horn straight down on main body; guiding accelerator pump plunger into its cylinder. Do not cut lip of plunger on sharp edge of cylinder. Install attaching screws and tighten to 25 inch pounds from center out. (6) Install accelerator pump arm, internal pump lever and pump operating shaft. On 2280 C-link and internal pump lever must be attached to accelerator pump shaft. Install "E" clip (Fig. 5). (7) To install fast idle connector link, engage plain end in slot of fast idle cam (from inside). Engage other end of rod in choke lever. With choke valve wide open, slide lever over choke shaft; (aligning flats). Install attaching lockwasher and nut. Tighten securely (Fig. 3). (8) Install accelerator pump link in No. 1 hole closest to Air Horn and retain with cotter pin on throttle lever end. (9) Engage choke diaphragm link in slot in choke lever. Install choke diaphragm assembly and secure with attaching screw (Fig. 2) Reinstall Vacuum Hose to Main Body. (10) Install bowl vent assembly (Fig. 1). (11) With pump links and levers installed, adjust the throttle blades to the closed position by backing out the idle speed screw. (12) Set the distance from the top of pump lever to the top of bowl vent cover surface to .050 +/.005 for 2280 models or .180" +/- .010" from 6280 models by bending the pump link. Check that wide open throttle can be reached without binding. (13) Install gasket and bowl vent cover plate. (14) Install Idle Stop Solenoid. (15) Install air cleaner bolt and retainer assembly. (16) Remove carburetor from repair stand. TSB 14-04-87 May 4, 1987 Publication #81-370-6007 Choke Vacuum Kick The choice diaphragm adjustment controls the fuel delivery while the engine is running. It positions the choke valve within the air horn by action of the linkage between the choke shaft and the diaphragm. The diaphragm must be energized to measure the vacuum kick adjustment. Vacuum can be supplied by an auxiliary vacuum source. Choke Unloader (Wide Open Kick) The choke unloader is a mechanical device to partially open the choke valve at wide open throttle. It is used to eliminate choke enrichment during cranking of an engine. Engines which have been flooded or stalled by excessive choke enrichment can be cleared by use of the unloader. Refer to carburetor adjustments for adjusting procedure. Fast Idle Speed Fast idle engine speed is used to overcome cold engine friction, stalls after cold starts and stalls because of carburetor icing. Refer to carburetor adjustments for procedure. Fast Idle Cam Position This adjustment is used to provide cam stop speeds at proper times during engine warmup. TSB 14-04-87 May 4, 1987 Publication #81-370-6007 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2360 5. MECHANICAL POWER VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate. (2) Hold throttle in wide open position, (3) Insert 5/64" Allen wrench in mechanical power valve adjustment screw. (4) Push screw down and release to determine if clearance exists. Turn screw clockwise until clearance is zero. (5) Adjust by turning screw counter clockwise one turn. (6) Install bowl vent gasket and cover plate. IF ACCELERATOR PUMP ADJUSTMENT IS CHANGED, THIS ADJUSTMENT MUST BE RESET. 6. ACCELERATOR PUMP STROKE MEASUREMENT 6280 MODELS (1) Remove bowl vent cover plate and gasket. (2) With pump link and levers installed, adjust the throttle blades to the closed position by backing out the idle speed screw. (3) Set the distance from the top of pump lever to the top of bowl vent cover surface to .180" +/.010" by bending the pump link. Check that wide open throttle can be reached without binding. (4) Install gasket and bowl vent cover plate. (5) Reset Idle Speed. TSB 14-04-87 May 4, 1987 Publication #81-370-6007 12. PROPANE ASSISTED IDLE SET PROCEDURE (2280 AND 6280 MODELS) RPM Chrysler No. Vendor No. 4324629 R-40214A Refer to VECI Label 4324631 R-40216A 4324632 R-40221A 4324633 R-40222A On a new vehicle (under 300 miles/500km) reduce RPM settings by 75 RPM. Tampering with the carburetor is a violation of Federal law. Adjustment of the carburetor idle air fuel mixture can only be done under certain circumstances as explained below. Upon completion of the adjustment, the concealment plugs must be replaced. This procedure should only be used if an idle defect still exists after normal diagnosis reveals Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2361 no other faulty condition such as incorrect basis timing, incorrect idle speed, faulty hose or wiring connections, etc. Adjustment of the carburetor air fuel mixture should be performed after a major carburetor overhaul. (1) Remove the concealment plug. Set the parking brake and place the transmission in neutral. Turn all lights and accessories off. Connect a tachometer to the engine. Start the engine and allow it to warm up on the second highest step of the fast idle cam until normal operating temperature is reached return the engine to idle and turn off engine. (2) Remove air cleaner, disconnect and plug the vacuum hoses at the EGR valve and ESA computer. No vacuum is to be applied to the computer. Disconnect and plug canister purge hose at canister. (3) Disconnect carburetor electrical connector. (4) Remove the PCV valve from the cylinder head and allow the valve to draw underhood air. (5) Start and run engine. (6) Disconnect the vacuum supply hose from the choke diaphragm at the carburetor and install the propane supply hose in its place. Other connections at the tee must remain in place. (7) With the propane bottle upright and in a safe location, open the propane main valve. Slowly open the propane metering valve until the maximum engine rpm is reached. When too much propane is added, engine rpm will decrease. "Fine tune" the metering valve to obtain the highest engine rpm. (8) With the propane still flowing, adjust the idle speed screw on the solenoid to obtain the correct propane rpm. Again, "fine tune" the metering valve to obtain the highest engine rpm. If there has been a change in the maximum rpm, readjust the idle speed screw to the specified propane rpm. (9) Turn off the propane main valve and allow the engine speed to stabilize. Slowly adjust the mixture screws by equal amounts, pausing between adjustments to allow engine speed to stabilize, to obtain the smoothest idle at the correct idle rpm. (10) Turn on the propane main valve end "Fine tune" the metering valve to obtain the highest engine rpm. If the maximum engine speed is more than 25 rpm different than the specified propane rpm, repeat steps (8) through (11). (11) Turn off propane main and metering valves. Remove the propane supply hose and reinstall the heated air sensor hose. Reinstall new concealment plugs. Reconnect vacuum line on ESA, reconnect carburetor electrical connector. Perform the Solenoid Idle Stop, Idle RPM, and Fast Idle Speed Adjustment Procedures. 13. ACCELERATOR PUMP STROKE MEASUREMENT 2280 MODELS (1) Remove bowl vent cover plate and vent valve lever/and spring. Caution: Do not dislodge or lose vent valve lever retainer. (2) With pump link in No.1 inner hole and levers installed, adjust the throttle blades to the closed position by backing out the idle speed screw. (3) Set the distance from the top of pump lever to the top of bowl vent cover surface to .050" +/.005" by bending the pump link. Check that wide open throttle can be reached without binding. (4) Install vent valve lever and spring and gasket and bowl vent cover plate. (5) Reset Idle Speed. NOTE: IF THIS ADJUSTMENT IS CHANGED, BOTH THE BOWL VENT AND THE MECHANICAL POWER VALVE ADJUSTMENTS MUST BE RESET. Publication #81-370-6008 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2362 FIGURE 15 - TESTING ACCELERATOR PUMP DISCHARGE CHECK BALL AND SEAT FIGURE 16 - SERVICING VACUUM POWER VALVE PISTON AND RETAINING RING FIGURE 17 - SERVICING MECHANICAL POWER VALVE PUSH ROD Publication #81-370-6008 Revised TSB 14-04-87 May 4, 1987 (3) Install mechanical power valve push rod spring, push rod spring, push rod and "E" clip retainer. Push plastic cap on to push rod (2280 models only) (Fig. 8). (4) Install accelerator pump plunger assembly through air horn and attach internal lever with Clink (2280 models only). On 6280 models, install new accelerator pump cup. (5) Place a new gasket on air horn. Lower air horn straight down on main body; guiding accelerator pump plunger into its cylinder. Do not cut lip of plunger on sharp edge of cylinder. Install attaching screws and tighten to 25 inch pounds from center out. (6) Install accelerator pump arm, internal pump lever and pump operating shaft. On 2280 C link and internal pump lever must be attached to accelerator pump shaft. Install "E" clip (Fig. 5). (7) To install fast idle connector link, engage plain end in slot of fast idle cam (from inside). Engage other end of rod in choke lever. With choke valve wide open, slide lever over choke shaft; (aligning flats). Install attaching lockwasher and nut. Tighten securely (Fig. 3). (8) Install accelerator pump link in No. 1 hole closest to Air Horn and retain with cotter pin on throttle lever end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2363 (9) Engage choke diaphragm link in slot in choke lever. Install choke diaphragm assembly and secure with attaching screw (Fig. 2) Reinstall Vacuum Hose to Main Body. (10) Install bowl vent assembly (Fig. 1). (11) With pump links and levers installed, adjust the throttle blades to the closed position by backing out the idle speed screw. (12) Set the distance from the top of pump lever to the top of bowl vent cover surface to .050 +/.005 for 2280 models or .180" +/- .010" for 6280 models by bending the pump link. Check that wide open throttle can be reached without binding. (13) Install gasket and bowl vent cover plate. (14) Install Idle Stop Solenoid. (15) Install air cleaner bolt and retainer assembly. (16) Remove carburetor from repair stand. TSB 14-04-87 May 4, 1987 Publication #81-370-6008 5. MECHANICAL POWER VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate. (2) Hold throttle in wide open position. (3) Insert 5/64" Allen wrench in mechanical power valve adjustment screw. (4) Push screw down and release to determine if clearance exists. Turn screw clockwise until clearance is zero. (5) Adjust by turning screw counter clockwise one turn. (6) Install bowl vent gasket and cover plate. If accelerator pump adjustment is changed, this adjustment must be reset. 6. ACCELERATOR PUMP STROKE MEASUREMENT (AT IDLE) 6280 (1) Remove bowl vent cover plate and gasket. (2) With pump link and levers installed, adjust the throttle blades to the closed position by backing out the idle speed screw. (3) Set the distance from the top of pump lever to the top of bowl vent cover surface to .180 +/.010" by bending the pump link. Check that wide open throttle can be reached without binding. (4) Install gasket and bowl vent cover plate. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2364 (5) Reset Idle Speed. TSB 14-04-87 May 4, 1987 Publication #81-370-6008 12. PROPANE ASSISTED IDLE SET PROCEDURE (2280 AND 6280 MODELS) RPM Chrysler No. Vendor No. 4324629 R-40214A Refer to 4324631 R-40216A VECI Label 4324632 R-40221A 4324633 R-40222A On a new vehicle (under 300 miles/500 km) reduce RPM settings by 75 RPM. Tampering with the carburetor is a violation of Federal law. Adjustment of the carburetor idle air fuel mixture can only be done under certain circumstances as explained below. Upon completion of the adjustment, the concealment plugs must be replaced. This procedure should only be used if an idle defect still exists after normal diagnosis reveals no other faulty condition such as incorrect basis timing, incorrect idle speed, faulty hose or wiring connections, etc. Adjustment of the carburetor air fuel mixture should be performed after a major carburetor overhaul. (1) Remove the concealment plug. Set the parking brake and place the transmission in neutral. Turn all lights and accessories off. Connect a tachometer to the engine. Start the engine and allow it to warm up on the second highest step of the fast idle cam until normal operating temperature is reached. Return the engine to idle and turn off engine. (2) Remove air cleaner, disconnect and plug the vacuum hoses at the EGR valve and ESA computer. No vacuum is to be applied to the computer. Disconnect and plug canister purge hose at canister. (3) Disconnect carburetor electrical connector. (4) Remove the PCV valve from the cylinder head cover and allow the valve to draw underhood air. (5) Start and run engine. (6) Disconnect the vacuum supply hose from the choke diaphragm at the carburetor and install the propane supply hose in its place. Other connections at the tee must remain in place. (7) With the propane bottle upright and in a safe location, open the propane main valve, Slowly open the propane metering valve until the maximum engine rpm is reached. When too much propane is added, engine rpm will decrease. "Fine tune" the metering valve to obtain the highest engine rpm. (8) With the propane still flowing, adjust the idle speed screw on the solenoid to obtain the correct propane rpm. Again, "fine tune" the metering valve to obtain the highest engine rpm. If there has been a change in the maximum rpm, readjust the idle speed screw to the specified propane rpm. (9) Turn off the propane main valve and allow the engine speed to stabilize. Slowly adjust the mixture screws by equal amounts, pausing between adjustments to allow engine speed to stabilize, to obtain the smoothest idle at the correct idle rpm. (10) Turn on the propane main valve and "Fine tune" the metering valve to obtain the highest engine rpm. If the maximum engine speed is more than 25 rpm different than the specified propane rpm, repeat steps 8 through 12. (11) Turn off propane main and metering valves. Remove the propane supply hose and reinstall the heated air sensor hose. Reinstall new concealment plugs. Reconnect vacuum line on ESA, reconnect carburetor electrical connector. Perform the Solenoid Idle Stop, Idle RPM, and Fast Idle Speed Adjustment Procedures. 13. ACCELERATOR PUMP STROKE MEASUREMENT 2280 MODELS (1) Remove bowl vent cover plate and vent valve lever/and spring. Caution: Do not dislodge or lose vent valve lever retainer. (2) With pump link in No. 1 inner hole and levers installed, adjust the throttle blades to the closed position by backing out the idle speed screw. (3) Set the distance from the top of pump lever to the top of bowl vent cover surface to .050" +/.005" by bending the pump link. Check that wide open throttle can be reached without binding. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2365 (4) Install vent valve lever and spring and gasket and bowl vent cover plate. (5) Reset Idle Speed. NOTE: IF THIS ADJUSTMENT IS CHANGED, BOTH THE BOWL VENT AND THE MECHANICAL POWER VALVE ADJUSTMENTS MUST BE RESET. Publication #81-370-6010 TSB 14-04-87 May 4, 1987 Publication #81-370-6010 5. ACCELERATOR PUMP STROKE MEASUREMENT 6280 MODELS (1) Remove bowl vent cover plate and gasket. (2) With pump links and levers installed, adjust the throttle blades to the closed position by backing out the idle speed screw. (3) Set the distance from the top of pump lever to the top of bowl vent cover surface to .180" +/.010" by bending the pump link. Check that wide open throttle can be reached without binding. (4) Install gasket and bowl vent cover plate. (5) Reset Idle Speed. 6. IDLE SPEED ADJUSTMENT Before checking or adjusting any idle speed, check ignition timing and adjust if necessary using the procedure shown in Group 8 Electrical. Disconnect and plug the vacuum hose at the EGR valve and air switching valve. Also disconnect and plug the vacuum hose from the carburetor at the heated air temperature sensor. Remove the air cleaner and disconnect and plug the 3/16 inch diameter control hose at the canister. Remove the PCV valve from the cylinder head cover and allow the valve to draw underhood air. Install tachometer. Start and run engine until normal operating temperature is reached. RPM Refer to VECI Label (1) Allow the engine to run for one minute for the engine speed to stabilize. (2) If the engine rpm is not correct, turn the idle speed screw to obtain the correct idle rpm. (3) Turn off engine. Unplug and reconnect vacuum hoses at EGR valve, canister, and air switching valve. (4) Reinstall air cleaner and unplug and reconnect vacuum hose from carburetor to heated air temperature sensor on air cleaner. Remove tachometer Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2366 and reinstall PCV valve. Idle speeds with the engine in normal operating condition (all hoses and wires connected) may vary from set speeds. DO NOT READJUST. Publication #81-370-7010 TSB 14-04-87 May 4, 1987 Publication #81-370-7010 5. ACCELERATOR PUMP STROKE MEASUREMENT (1) Remove bowl vent cover plate and gasket. (2) With pump links and levers installed, adjust the throttle blades to the closed position by backing out the idle speed screw. (3) Set the distance from the top of pump lever to the top of bowl vent cover surface to .180" +/.010" by bending the pump link. Check that wide open throttle can be reached without binding. (4) Install gasket and bowl vent cover plate. (5) Reset Idle Speed. 6. IDLE RPM ADJUSTMENT Before checking or adjusting any idle rpm, check ignition and adjust, if necessary, using procedure in Group 8, Electrical. Ground the carburetor switch on vacuum kicker with jumper wire. Disconnect and plug the vacuum hose at the air switching valve, Disconnect and plug the 3/16 in. diameter canister purge control hose at the solenoid. Remove the PCV valve from the cylinder head cover and allow the valve to draw underhood air. Install tachometer. Start and run engine until normal operating temperature is reached. RPM Refer to VECI Label (1) Allow the engine to run for one minute for the engine speed to stabilize. (2) If the engine rpm is not correct, turn the idle speed screw to obtain the correct idle rpm. (3) Turn off engine. Unplug and reconnect vacuum hoses at canister, and air switching valve. (4) Remove tachometer and reinstall PCV valve. Idle speeds with the engine In normal operating condition (all hoses and wires connected) may vary from set speeds. DO NOT READJUST. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Jet > Component Information > Technical Service Bulletins > High Altitude Conversion Package Technical Service Bulletin # 250485 Date: 850506 High Altitude Conversion Package Models 1985 Light Duty Domestic Trucks Subject High Altitude Conversion Packages & Adjustment for Improved Engine Performance Index EMISSIONS Date May 6, 1985 No.. 25-04-85 P-1522-C Packages are now available to accommodate a customer who wishes to convert his 1985 low altitude vehicle for improved high altitude (over 4,000 feet above sea level) engine performance. Vehicles with the low altitude package transferred to service in high altitude areas may exhibit undesirable driveability. However, the installation of a high altitude conversion package is voluntary and at the customer's expense. The high altitude field conversion packages and procedures outlined below have been authorized on the following 1985 non-altitude equipped engine families in service at altitudes above 4,000 feet above sea level. CONVERSION INSTRUCTIONS Sea Level to Altitude FIGURE 1 - Vehicle Emission Control Information Label IMPORTANT: IN SOME OF THE CONVERSION PROCEDURES YOU WILL BE REQUIRED TO INSTALL A NEW VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL PN 4275084. THIS LABEL HAS TWO AREAS THAT ARE IMPACT IMPRINTABLE WITH A TYPEWRITER (SEE FIGURE 1). If you are required to readjust timing, curb idle speed, or fast idle speed to a specification different than the original VECI label specification, then just type in the new specification after the subject operation. If you are asked to refer to the original VECI label specifications, type in on the right hand side of the label "Refer to Original VECI Label." Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Jet > Component Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2371 In every case where this label is used, type in after - AUTHORITY OF Technical Service Bulletin #25-04-85, and your dealer code below. Label PN 4275084 is available from Parts Supply. FIGURE 2 - Vehicle Emission Control Information Label The engine family chart below will help identify the appropriate parts to be installed by recording body style and engine family from the original VECI label. This chart cross references the EPA engine family with the engine application used in the accompanying instructions (refer to Figure 2). EPA Engine Family Engine Application (Found on VECI Label) 2.2L-2V Federal FCR2.2T2AAB6 2.2L-2V 50 States FCR2.2T2HBM9 2.6L-2V Federal FCR2.6T2AAB8 3.7L-1V Federal FCR3.7T1BBA0 5.2L-2V 50 States FCR5.2T2HBN1 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Jet > Component Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2372 5.2L-2V Federal FCR5.2T2BBF6 5.9L-4V Federal FCR5.9T4BBF1 POLICY: Information only 1985 2.2L-2V Light Duty Trucks All Models With Federal Emissions Package (49 States) Dodge Ram Van, Dodge Caravan, Plymouth Voy Consisting of: 1 - #211 Primary Main Jet PN 4293797 1 - #215 Secondary Main Jet PN 4240006 1 - #180 Primary High Speed Bleed PN 4342920 1 - #210 Secondary High Speed Bleed PN 4342921 1 - Carburetor Air Horn Gasket PN 4293846 INSTRUCTIONS FIGURE 1. Holley 5220 Primary Main Metering Jet #211 FIGURE 2. Holley 5220 Secondary Main Metering Jet #223 - Remove carburetor air horn. - Remove primary and secondary main metering jets. Refer to Figures 1 and 2. - Install #211 primary main metering jet PN 4293797. - Install #215 secondary main metering jet PN 4240006. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Jet > Component Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2373 FIGURE 3. Holley 5220 Primary High Speed Bleed #180 FIGURE 4. Holley 5220 Secondary High Speed Bleed #210 - Remove primary and secondary high speed bleeds. Refer to Figures 3 and 4. - Install #180 primary high speed bleed PN 4342920. - Install #210 secondary high speed bleed PN 4342921. FIGURE 5. Holley 5220 Power Valve Location - Turn power valve (Figure 5) two full turns counterclockwise (lean). - Reinstall air horn with new air horn gasket PN 4293846. Start engine and check for leaks. - Warm up engine and set idle speed to that specified on the VECI label. - Type in changes made on Emission Update Label PN 4275084 and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Jet > Component Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2374 1985 2.2L-2V Light Duty Truck Dodge Ram Van, Dodge Caravan & Plymouth Voyager Only Equipped With "50 States" Emission Package Consisting of: 1 - Carburetor (manual or automatic PN 4342891 transmission) Also order conversion hardware package. 1 - Hardware Package PN 4342950 Consisting of: 1 - Carburetor Base Gasket PN 4095975 1 - H.A.C. PN 4306202 1 - Hose Routing Diagram NPN 1 - Mounting Bracket (H.A.C.) PN 4105199 1 - H.A.C. Hose Harness NPN 3 - Mounting Screws NPN INSTRUCTIONS - Remove carburetor per instructions in appropriate engine performance/electrical shop manual. - Install new carburetor with new base gasket. FIGURE 6 - High Altitude Compensator Mounting - Install altitude compensator with bracket (Figure 6). - Install altitude compensator vacuum hose harness, route as shown in hose routing diagram (Figure 6). - Warm up engine. - Set engine idle speed to specified VECI label specification. - Set high fast idle on Step 3 (lowest) to specification. - Double check hose routing and installation of fuel lines. - Type in changes made on the Emission Update Label PN 4275084 and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Jet > Component Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2375 1985 2.6L-2V Light Duty Truck All Models With Federal Emissions Package (49 States) Consisting of: 1 - Carburetor Jet Kit PN MD088294 containing: #110 Primary Main Jet #175 Secondary Main Jet #100 Primary Air Bleed Jet #120 Secondary Air Bleed Jet 1 - Float Chamber Cover Gasket PN MD608639 1 - Choke Cover Screw Kit PN MD606977 1 - Carburetor Flange Gasket PN MD025344 INSTRUCTIONS - Remove carburetor from engine and take off air horn per instructions in appropriate service manual. FIGURE 7 - Mikuni Jet Locations - Remove primary and secondary main jets as shown in Figure 7. - Install #110 primary main jet and #175 secondary main jet in the primary and secondary pedestals. - Reinstall air horn on carburetor using new air horn gasket PN MD608639 and choke cover screw kit PN MD606977. FIGURE 8 - Mikuni Air Bleed Jet Locations - Remove primary and secondary air bleed jets shown in Figure 8. - Prepare carburetor for propane idle set by drilling out concealment plug. - Install #120 secondary air bleed jet and #100 primary air bleed jet. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Jet > Component Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2376 - Reinstall carburetor on engine using a new carburetor flange gasket, PN MD025344. - Remove vacuum controlled orificed tank vapor valve (VCOTV) and the vacuum/line(s) to the valve. - Remove the 3/16" tank vent line from the vapor canister and replace with 24" of 3/16" tank vent line and route directly to steel tank vent tube. - Remove the manifold vacuum line from the manifold vacuum tee (originally to the VCOTV) and cap the tee. - Remove the EGR delay valve at the corresponding EGR and carburetor ports and replace with 8" of bulk 3/16" vacuum line from stock. - Start engine and warm up to operating temperature. - Set idle rpm (curb) to 850 rpm and propane enriched rpm to 950 rpm. - Set throttle kicker rpm to 1050 rpm. FIGURE 9 - Authorized Modifications Label - Type in changes made on Authorized Modification Label, PN 4275086 (Figure 9), and affix to engine compartment next to VECI label. 1985 3.7L-1V Light Duty Trucks All Models With Federal Emission Package (49 States) Consisting of: 1 - #611 Main Metering Jet PN 3837520 1 - Carburetor Air Horn Gasket PN 4267140 INSTRUCTIONS - Remove carburetor. - Remove air horn from carburetor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Jet > Component Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2377 FIGURE 10 - Main Metering Jet Location - Remove existing main metering jet (Figure 10). - Install #611 main metering jet PN 3837520. - Reinstall air horn with new air horn gasket PN 4267140. - Drill out concealment plug and prepare carburetor for propane idle set. - Per instructions in appropriate service manual, perform a propane idle set. Reset the propane/curb idle speeds to 775/750 for manuals and 800/775 for automatics. - Reset HFI to 1600 on Step 2. - Reset choke vacuum kick to 0.120". - Reset idle solenoid speed to 850 rpm (manual transmission) or 875 (automatic transmission). - Type in changes made on Emission Update Label and affix in engine compartment next to VECI label. 1985 5.2L-2V Light Duty Trucks All Models With "50 States" Emissions Packages Consisting of: 1 - Carburetor PN 4306453 1 - EGR Valve PN 4094891 1 - EGR Valve Gasket PN 4287938 1 - Carburetor Gasket PN 4095970 INSTRUCTIONS Using procedures as outlined in the appropriate service manual, perform the following: - Remove existing carburetor. - Install replacement carburetor PN 4306453 and gasket. - Remove EGR valve and scrape off old gasket material. - Install replacement EGR valve PN 4094891 and new gasket PN 4287938. - Start engine and check for leaks. - Check and reset if necessary, curb idle, fast idle to VECI label specifications. - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. - The high altitude adjustments are now complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Jet > Component Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2378 1985 5.2L-2V Light Duty Trucks All Models With Federal Emissions Package (49 States) Consisting of: 2 - Main Metering Jet #147 PN 4271983 1 - EGR Valve PN 4287678 1 - EGR Valve Gasket PN 4287938 1 - Carburetor Base Gasket PN 4095970 INSTRUCTIONS Per instructions in appropriate service manual, perform the following: - Remove carburetor from engine. - Remove air horn from carburetor. FIGURE 11 - Holley 2280 Main Metering Jets - Remove existing main metering jet (Figure 11). - Install main metering jets provided, PN 4271983. - Adjust vacuum kick to 0.150". - Adjust mechanical unloader to 0.280". - Remove EGR valve and scrape off old gasket material. - Install new EGR valve PN 4287678 with new gasket PN 4287938. - Start engine, check for leaks. - Prepare carburetor for propane idle set and reinstall on engine using gasket PN 4095970. - Start engine and check for leaks. - Perform propane idle adjustment to 700 rpm (curb idle) and 770 rpm (propane enriched idle). - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. 5.9L-4V Light Duty Trucks All Automatic Models With Federal Emissions Package Consisting of: 1 - Carburetor PN 4342807 1 - EGR Valve PN 4287659 1 - Carburetor Base Gasket PN 3698365 1 - EGR Valve Gasket PN 4287938 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Jet > Component Information > Technical Service Bulletins > High Altitude Conversion Package > Page 2379 INSTRUCTIONS - Remove existing carburetor. - Install new carburetor PN 4342807 along with new carburetor base gasket PN 3698365. - Raise the rear wheels of the vehicle with the transmission in neutral. Rotate the rear wheels through one revolution and determine the axle ratio. - If the vehicle has a 3.55 or 4.10 axle, replace EGR valve with PN 4287659 and gasket PN 4287938. - Start engine and check for leaks. - Type in changes made on Emission Update Label and affix to engine compartment next to VECI label. 5.9L-4V Light Duty Trucks All Manual Models With Federal Emission Package Consisting of: 1 - Carburetor PN 4342807 1 - Carburetor Base Gasket PN 3698365 INSTRUCTIONS - Remove original carburetor. - Install replacement carburetor PN 4342807 using new base gasket PN 3698365. - Start engine and check for leaks. - Type in changes made on Emission Update Label PN 4275084 and affix to engine compartment next to original VECI label. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Idle Enrichment Switch <--> [Carburetor Solenoid] > Component Information > Description and Operation Idle Enrichment Switch: Description and Operation Fig. 44 Idle enrichment system The idle enrichment system, Fig. 44, improves cold engine driveability by using a metering system related to the basic carburetor instead of the choke. During cold engine operation, the complete idle system will be enriched. Idle system air is controlled by a small diaphragm mounted near the top of the carburetor. When control vacuum is applied to the diaphragm, idle system air is reduced, resulting in an increased fuel flow and a richer air/fuel mixture. The vacuum signal to the carburetor diaphragm is controlled by a thermal switch which is in contact with the engine coolant flow. When the engine is cold, the switch is open and the vacuum signal is passed to the diaphragm. As the engine warms, the switch closes, eliminating the vacuum signal and returning the carburetor metering to normal, lean levels. On some systems, this engine coolant vacuum switch controls the duration of idle system enrichment. In other systems, similar coolant vacuum switches are used, but the switch receives its vacuum signal from a solenoid valve operated by an electric timer. Idle enrichment will last for approximately 35 seconds. When the engine warms, the thermal switch will prevent additional cycles of idle enrichment, however, when the engine is cold, each restart will cycle the enrichment for an additional 35 seconds. The switches used in solenoid controlled systems close at approximately 150° F., while others close at approximately 98° F. All switches open at approximately 12° F. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Pull-off > Component Information > Technical Service Bulletins > Choke Unloader - Service Manual Correction Choke Pull-off: Technical Service Bulletins Choke Unloader - Service Manual Correction Models 1985-1987 Pick Up, Ram Van, & Ram Van Wagon Subject Service Manual Correction Index FUEL Date December 29, 1986 No. 14-09-86 P-4584 SYMPTOM/CONDITION This Technical Service Bulletin updates the following service manuals in Group 14, Fuel, to the latest procedures for adjusting the choke unloader. 1985 Ram Van & Wagon 81-370-5007 Page 14-20 1986 Ram Van & Wagon 81-370-6007 Page 14-17 1987 Ram Van & Wagon 81-370-7007 Page 14-24 1985 Ramcharger & Pick Up 81-370-5008 Page 14-20 1986 Ramcharger & Pick Up 81-370-6008 Page 14-17 1987 Ramcharger & Pick Up 81-370-7008 Page 14-26 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Pull-off > Component Information > Technical Service Bulletins > Choke Unloader - Service Manual Correction > Page 2387 REPAIR PROCEDURE The attached page has six identical pictures to illustrate the proper choke unloader adjustment procedure. Cut this page into six sections and tape, staple, glue, or otherwise attach a picture to the pages of the service manuals listed above. POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Pull-off > Component Information > Technical Service Bulletins > Page 2388 Choke Pull-off: Locations Engine Mounted Switches & Sensors. RH Side Of Engine Applicable to: 6 Cylinder Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Temperature Control Switch > Component Information > Locations Choke Temperature Control Switch: Locations Upper RH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Customer Interest for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts Technical Service Bulletin # 181986 Date: 860210 Choke - Hard Hot Restarts Models All 1985-1986 Cars & Trucks Equipped With Quadrajet 4-BBL Carburetors (318-360) Subject Premature Choke Closing Causing Hard Hot Restarts Index DRIVEABILITY Date February 10, 1986 No. 18-19-86 P-362-C Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Partial choke closure which results in a rich condition causing hard worm and hard hot starts in cool or cold ambients. The vehicle may exhibit block smoke out the tailpipe for the first few miles of driving. DIAGNOSIS Remove the air cleaner and visually verify the choke blade is closing when the engine is worm or hot while the ambient is cool or cold. PARTS REQUIRED For 318 4BBL Passenger Cars and 318/360 4BBL D and W Trucks Driveability PN 4397683 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose (Preformed) PN 4361146 1 Heater Hose PN 3849197 1 Screw PN 3730000 "M" body cars will require the following to be ordered separately: 1 Water Valve PN 4085474 3 Tie Wraps PN 6015756 For 318 4BBL Police Vehicles With Silicone Hoses Only Driveability Package PN 4397684 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose (Preformed Silicone) PN 3849564 1 Heater Hose Silicone PN 3849472 1 Water Valve PN 4085474 1 Screw PN 3730000 3 Tie Wraps PN 6015756 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Customer Interest for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 2400 For 318 4BBL/360 4BBL "B" Model Vans Driveability Package PN 4397685 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose PN 4361142 3 Tie Wraps PN 6015756 1 Screw PN 3730000 To be ordered separately for all vehicles: 1 Authorized Modification Label PN 4275086 Repair Procedures This repair procedure involves the routing of the heater supply hose so it contacts the choke housing. The heat from this hose reduces the tendency of the choke to close before the engine cools off. It is, therefore, very important the heater hose be in direct contact with the choke housing. "M" Body Passenger Cars and D-W Series Trucks Without Silicone Heater Hoses and With Air Conditioning 1. Remove and discard the supply heater hoses and the water control valve. This is the hose that connects the intake manifold to the heater core. 2. Remove the return heater hose from the heater core at the cowl and install it on the opposite nipple of the heater core. 3. Remove and discard 33 inches off the straight end of the preformed hose, PN 4361146. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Customer Interest for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 2401 FIGURE 2 4. Clamp water valve, PN 4085474, onto the straight end of heater hose, PN 4361146, which was cut off in Step 3 above. This water valve has an embossed arrow on it to indicate water flow. This arrow must point toward the heater core or precise control of water flow to the heater will be impossible. Proper orientation of this valve is illustrated in Figure 2. Install heater hose, PN 3849197, on the other side of the water valve. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Customer Interest for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 2402 FIGURE 1 5. Attach supply heater hose bracket, PN 4307576, to the intake manifold boss using enclosed screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Customer Interest for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 2403 FIGURE 3 6. Install the 90~ bend of the supply heater hose and valve assembly onto the nipple on intake manifold. Route the supply hose past the carburetor choke housing and install the straight end of the hose onto the heater core inlet nipple. Install heater hose onto bracket and clamp securely in place (see Figure 3). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Customer Interest for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 2404 FIGURE 6 7. Attach Authorization Modification Label, PN 4275086, as illustrated in Figure 6. "M" Body Police With Silicone Heater Hoses 1. Follow the same installation procedure as on "M" body passenger car except silicone heater hose, PN 3849564, must be substituted for passenger car hose, PN 4361146. Silicone heater hose, PN 3849472, must be substituted for passenger car heater hose, PN 3849197. FIGURE 6 2. Attach Authorization Modification Label, PN 4274086, as illustrated in Figure 6. D and W Model Trucks Without Air Conditioning 1. Remove and discard the supply heater hose that connects the intake manifold to the heater core. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Customer Interest for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 2405 FIGURE 1 2. Attach heater hose bracket to intake manifold boss using screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Customer Interest for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 2406 FIGURE 5 3. Install 90~ bend of heater supply hose, PN 4361146, onto the intake manifold nipple. Route this hose post carburetor choke housing and install straight end of hose on the heater core nipple. Install hose into bracket and clump hose securely in place (see Figure 5). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Customer Interest for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 2407 FIGURE 6 4. Attach Authorization Modification Label, PN 4274086, as illustrated in Figure 6. "B" Model Van With and Without Air Conditioning 1. Remove and discard supply heater hose that connects the intake manifold to the heater core or to the water valve, if the vehicle is air conditioning equipped. FIGURE 1 2. Attach heater hose bracket, PN 4307576, to intake manifold boss using screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Customer Interest for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 2408 3. Install 90~ end of supply heater hose, PN 4361142, onto the intake manifold nipple. Route this heater supply hose post the carburetor choke housing and install the straight end on the heater core or on the water valve, if the vehicle has air conditioning. This hose must be cut to length as required. Install this heater supply hose into the hose bracket previously attached to the intake manifold. FIGURE 4 4. Using tie wraps, PN 6015756, secure supply heater hose to automatic transmission dip stick tube. Use caution as not to deform dip stick tube, as this will make transmission fluid level checks difficult or impossible. Using tie wraps, tie the supply and return heater hoses together as illustrated in Figure 4. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Customer Interest for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 2409 FIGURE 6 5. Attach Authorization Modification Label, PN 4275086, as illustrated in Figure 6. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 14-30-56-96 Premature Choke Closing "B" Van 0.7 Hrs. D-W Truck and "M" Body Passenger Car 0.5 Hrs. 14-30-56-97 Optional Equipment Air Conditioning "B" Van 0.3 Hrs. D-W Truck and "M" Body Passenger Car 0.4 Hrs. FAILURE CODE: AM - Authorized Modification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Customer Interest for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 2410 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts Technical Service Bulletin # 181986 Date: 860210 Choke - Hard Hot Restarts Models All 1985-1986 Cars & Trucks Equipped With Quadrajet 4-BBL Carburetors (318-360) Subject Premature Choke Closing Causing Hard Hot Restarts Index DRIVEABILITY Date February 10, 1986 No. 18-19-86 P-362-C Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Partial choke closure which results in a rich condition causing hard worm and hard hot starts in cool or cold ambients. The vehicle may exhibit block smoke out the tailpipe for the first few miles of driving. DIAGNOSIS Remove the air cleaner and visually verify the choke blade is closing when the engine is worm or hot while the ambient is cool or cold. PARTS REQUIRED For 318 4BBL Passenger Cars and 318/360 4BBL D and W Trucks Driveability PN 4397683 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose (Preformed) PN 4361146 1 Heater Hose PN 3849197 1 Screw PN 3730000 "M" body cars will require the following to be ordered separately: 1 Water Valve PN 4085474 3 Tie Wraps PN 6015756 For 318 4BBL Police Vehicles With Silicone Hoses Only Driveability Package PN 4397684 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose (Preformed Silicone) PN 3849564 1 Heater Hose Silicone PN 3849472 1 Water Valve PN 4085474 1 Screw PN 3730000 3 Tie Wraps PN 6015756 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 2416 For 318 4BBL/360 4BBL "B" Model Vans Driveability Package PN 4397685 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose PN 4361142 3 Tie Wraps PN 6015756 1 Screw PN 3730000 To be ordered separately for all vehicles: 1 Authorized Modification Label PN 4275086 Repair Procedures This repair procedure involves the routing of the heater supply hose so it contacts the choke housing. The heat from this hose reduces the tendency of the choke to close before the engine cools off. It is, therefore, very important the heater hose be in direct contact with the choke housing. "M" Body Passenger Cars and D-W Series Trucks Without Silicone Heater Hoses and With Air Conditioning 1. Remove and discard the supply heater hoses and the water control valve. This is the hose that connects the intake manifold to the heater core. 2. Remove the return heater hose from the heater core at the cowl and install it on the opposite nipple of the heater core. 3. Remove and discard 33 inches off the straight end of the preformed hose, PN 4361146. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 2417 FIGURE 2 4. Clamp water valve, PN 4085474, onto the straight end of heater hose, PN 4361146, which was cut off in Step 3 above. This water valve has an embossed arrow on it to indicate water flow. This arrow must point toward the heater core or precise control of water flow to the heater will be impossible. Proper orientation of this valve is illustrated in Figure 2. Install heater hose, PN 3849197, on the other side of the water valve. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 2418 FIGURE 1 5. Attach supply heater hose bracket, PN 4307576, to the intake manifold boss using enclosed screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 2419 FIGURE 3 6. Install the 90~ bend of the supply heater hose and valve assembly onto the nipple on intake manifold. Route the supply hose past the carburetor choke housing and install the straight end of the hose onto the heater core inlet nipple. Install heater hose onto bracket and clamp securely in place (see Figure 3). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 2420 FIGURE 6 7. Attach Authorization Modification Label, PN 4275086, as illustrated in Figure 6. "M" Body Police With Silicone Heater Hoses 1. Follow the same installation procedure as on "M" body passenger car except silicone heater hose, PN 3849564, must be substituted for passenger car hose, PN 4361146. Silicone heater hose, PN 3849472, must be substituted for passenger car heater hose, PN 3849197. FIGURE 6 2. Attach Authorization Modification Label, PN 4274086, as illustrated in Figure 6. D and W Model Trucks Without Air Conditioning 1. Remove and discard the supply heater hose that connects the intake manifold to the heater core. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 2421 FIGURE 1 2. Attach heater hose bracket to intake manifold boss using screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 2422 FIGURE 5 3. Install 90~ bend of heater supply hose, PN 4361146, onto the intake manifold nipple. Route this hose post carburetor choke housing and install straight end of hose on the heater core nipple. Install hose into bracket and clump hose securely in place (see Figure 5). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 2423 FIGURE 6 4. Attach Authorization Modification Label, PN 4274086, as illustrated in Figure 6. "B" Model Van With and Without Air Conditioning 1. Remove and discard supply heater hose that connects the intake manifold to the heater core or to the water valve, if the vehicle is air conditioning equipped. FIGURE 1 2. Attach heater hose bracket, PN 4307576, to intake manifold boss using screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 2424 3. Install 90~ end of supply heater hose, PN 4361142, onto the intake manifold nipple. Route this heater supply hose post the carburetor choke housing and install the straight end on the heater core or on the water valve, if the vehicle has air conditioning. This hose must be cut to length as required. Install this heater supply hose into the hose bracket previously attached to the intake manifold. FIGURE 4 4. Using tie wraps, PN 6015756, secure supply heater hose to automatic transmission dip stick tube. Use caution as not to deform dip stick tube, as this will make transmission fluid level checks difficult or impossible. Using tie wraps, tie the supply and return heater hoses together as illustrated in Figure 4. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 2425 FIGURE 6 5. Attach Authorization Modification Label, PN 4275086, as illustrated in Figure 6. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 14-30-56-96 Premature Choke Closing "B" Van 0.7 Hrs. D-W Truck and "M" Body Passenger Car 0.5 Hrs. 14-30-56-97 Optional Equipment Air Conditioning "B" Van 0.3 Hrs. D-W Truck and "M" Body Passenger Car 0.4 Hrs. FAILURE CODE: AM - Authorized Modification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electric Assist Choke: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 2426 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Locations > Choke Heater Electric Assist Choke: Locations Choke Heater Engine Mounted Switches & Sensors. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Locations > Choke Heater > Page 2429 Engine Mounted Switches & Sensors. Upper RH Side Of Engine Applicable to: V8 Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Locations > Choke Heater > Page 2430 Electric Assist Choke: Locations Thermostatic Choke Coil Electric Assist Choke System Components On Side Of Carburetor Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Locations > Page 2431 Electric Assist Choke: Description and Operation 6-225 & V8 ENGINES LESS ROCHESTER CARBURETOR Fig. 32 Electric assist choke system. 6-225 & V8 engines less Rochester Quadrajet Carburetor Fig. 33 Choke heating element. 6-225 & V8 engines less Rochester Quadrajet Carburetor Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Locations > Page 2432 Fig. 34 Choke control switch. 6-225 & V8 engines less Rochester Quadrajet Carburetor The electric assist choke, Fig. 32, is used to reduce carbon monoxide (CO) and hydrocarbon (HC) emission during engine starting and warm-up. The choke thermostatic coil spring reacts to engine temperature, however, an electric heating element next to a bimetallic spring in the choke well will assist engine heat to shorten choke duration, Fig. 33. The wattage of the choke heater is part of the choke calibration and may change from year to year. The single stage electric assist choke will provide a more rapid choke opening at temperatures above approximately 60° F., and a slower choke opening below 60° F. A wire from the choke heater is connected to an electrical control switch, Fig. 34. An oil pressure switch is connected in series with the control switch to prevent early choke opening. As oil pressure increases, the choke control receives current. At 60° F. and above, the choke heater is energized by the control switch. Since the heater control switch is mounted on the engine, some cold weather operation may energize the choke heater. This could happen after the choke has opened without benefit of electric heat. This condition will not have an adverse effect on engine operation, and will soon be turned off. The dual stage control switch shortens choke duration at temperatures above 80°F. and stabilizes choke duration during cold weather operation. Cold weather heat levels are regulated by an electrical resistor connected to both terminals of the control. At temperatures below 55°F., electrical power to the choke heating element is reduced by the resistor. At temperature above 80°F., the resistor is bypassed by a switch inside the control to supply full electrical power to the choke heater unit. When the engine is started during cold weather conditions two levels of choke heat will be experienced, low during engine warm-up and high after engine warm-up. High heat levels occur after the choke is open to ensure an open choke condition under all driving conditions and minimize choking action which can occur after short stops during cold weather operation. Engines started in hot weather conditions will not experience low choke heat levels, as the switch is normally warmer than 80°F. The heating element should not be exposed to, or immersed in, any fluid for any reason. An electric short in the wiring to the heater or within the heater will be a short in the ignition system. V8 ENGINES WITH ROCHESTER CARBURETOR Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Locations > Page 2433 Fig. 35 Choke system. Rochester Quadrajet carburetor An off-set choke valve is mounted in the air horn above the primary venturi, Fig. 35. When closed, this choke valve provides the correct air/fuel mixture enrichment for cold engine starting. The choke valve will also assist in engine operation during warm-up. An electric choke coil located in the choke housing combined with the off-set choke valve and throttle position, control choke operation. To reduce choke closing during engine cool down, the heater hose is routing to contact the choke housing. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Float Bowl Air Vent Valve > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions Technical Service Bulletin # 140487 Date: 870504 Carburetor Adjustments - Manual Revisions Models 1984-1987 "D" Truck & "B" Van 1987 "N" Truck 1985-1987 "M" Body Subject Accelerator Pump & Bowl Vent - Adjustment - Service Manual Revisions Index FUEL Date May 4, 1987 No. 14-04-87 (C1-14) This bulletin is issued to revise the accelerator pump and bowl vent adjustment procedures. Corrections to the service manual are listed below. Use the charts provided to make the necessary changes and/or replace the pages as required. On the service manual publications listed below, replace the entire bowl vent valve adjustment procedure, including the picture, with the procedure and picture provided. NOTE: THE NEW PROCEDURE IS SHOWN IN DUPLICATE TO REDUCE PRINTING. USE ONLY 1/2 OF THE ATTACHMENT PER PAGE. Manual Publication No. Page No. 1984 RWD Van 81-370-4007 14-61 Add Item 1984 RWD Truck 81-370-4008 14-61 Add Item 1985 RWD Van 81-370-5007 14-60, Item 7 1985 RWD Truck 81-370-5008 14-60, Item 7 1986 RWD Van 81-370-6007 14-51, Item 7 1986 RWD Truck 81-370-6008 14-50, Item 7 1987 RWD Van 81-370-7007 14-58, Item 8 1987 RWD Truck 81-370-7008 14-60, Item 8 1987 RWD Car 81-270-7001 14-21, Item 8 In the following three service manuals it will be necessary to correct the accelerator pump adjustment specification. Change the .135" +/- .010" to .180" +/- .010" as listed below. 1. 1987 Rear Wheel Drive Car - Publication #81-270-7001, pages 14-17, Step 12 and page 14-20, Step 3. 2. 1987 Rear Wheel Drive Truck - Publication #81-370-7008 pages 14-56, Step 12 and page 14-60, Step 3. 3. 1987 Rear Wheel Drive Van - Publication #81-370-7007, pages 14-54, Step 12 and 14-58, Step 3. Using the following chart, replace the pages as indicated with the revised pages supplied. Service Manual Publication No. Revised Pages 1985 Rear Wheel Drive Car 81-270-5001 14-25 1986 Rear Wheel Drive Car 81-270-6001 14-16, 14-17, 14-20, 14-21 & 14-23 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Float Bowl Air Vent Valve > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2438 1986 Rear Wheel Drive Van 81-370-6007 14-46, 14-47, 14-50 & 14-54 1986 Rear Wheel Drive Truck 81-370-6008 14-45, 14-49 & 14-54 1987 Dakota 81-370-6010 14-32 1987 Dakota 81-370-7010 14-40 POLICY: Information only Publication #81-370-4007 TSB 14-04-87 May 4, 1987 Publication #81-370-4007 Page 14-61 BOWL VENT VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate and vent valve lever spring. CAUTION: Do not dislodge or misplace vent valve lever retainer/pivot pin. (2) With the throttle in the curb idle position, press firmly down on the vent valve lever where the spring seats; with another finger of the same hand, simultaneously press down on the vent valve tang until the vent valve is lightly seated (closed). CAUTION: If the carburetor is not on the engine, it must be on a raised fixture so as not to change the curb idle throttle plate position. (3) Using the other hand, measure the resulting gap between the contact surfaces of the vent valve lever and the vent valve tang with an appropriate gauge. (4) Adjust by bending the end of the vent valve lever up or down until the specified gap (.030") is set. (5) Install vent valve lever spring and bowl vent cover plate. NOTE: THE BOWL VENT VALVE AJUSTMENT MUST BE RESET IF THE ACCELERATOR PUMP ADJUSTMENT IS CHANGED. Publication #81-370-4008 TSB 14-04-87 May 4, 1987 Publication #81-370-4008 Page 14-61 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Float Bowl Air Vent Valve > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2439 BOWL VENT VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate and vent valve lever spring. CAUTION: Do not dislodge or misplace vent valve lever retainer/pivot pin. (2) With the throttle in the curb idle position, press firmly down on the vent valve lever where the spring seats; with another finger of the same hand, simultaneously press down on the vent valve tang until the vent valve is lightly seated (closed). CAUTION: If the carburetor is not on the engine, it must be on a raised fixture so as not to change the curb idle throttle plate position. (3) Using the other hand, measure the resulting gap between the contact surfaces of the vent valve lever and the vent valve tang with an appropriate gauge. (4) Adjust by bending the end of the vent valve lever up or down until the specified gap (.030") is set. (5) Install vent valve lever spring and bowl vent cover plate. NOTE: THE BOWL VENT VALVE ADJUSTMENT MUST BE RESET IF THE ACCELERATOR PUMP ADJUSTMENT IS CHANGED. Publication #81-370-5007 TSB 14-04-87 May 4, 1987 Publication #81-370-5007 Page 14-60 7. BOWL VENT VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate and vent valve lever spring. CAUTION: Do not dislodge or misplace vent valve lever retainer/pivot pin. (2) With the throttle in the curb idle position, press firmly down on the vent valve lever where the spring seats; with another finger of the same hand, simultaneously press down on the vent valve tang until the vent valve is lightly seated (closed). CAUTION: If the carburetor is not on the engine, it must be on a raised fixture so as not to change. the curb idle throttle plate position. (3) Using the other hand, measure the resulting gap between the contact surfaces of the vent valve lever and the vent valve tang with an appropriate gauge. (4) Adjust by bending the end of the vent valve lever up or down until the specified gap (.030") is set. (5) Install vent valve lever spring and bowl vent cover plate. NOTE: THE BOWL VENT VALVE ADJUSTMENT MUST BE RESET IF THE ACCELERATOR PUMP ADJUSTMENT IS CHANGED. Publication #81-370-5008 TSB 14-04-87 May 4, 1987 Publication #81-370-5008 Page 14-60 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Float Bowl Air Vent Valve > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2440 7. BOWL VENT VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate and vent valve lever spring. CAUTION: Do not dislodge or misplace vent valve lever retainer/pivot pin. (2) With the throttle in the curb idle position, press firmly down on the vent valve lever where the spring seats; with another finger of the same hand, simultaneously press down on the vent valve tang until the vent valve is lightly seated (closed). CAUTION: If the carburetor is not on the engine, it must be on a raised fixture so as not to change the curb idle throttle plate position. (3) Using the other hand, measure the resulting gap between the contact surfaces of the vent valve lever and the vent valve tang with an appropriate gauge. (4) Adjust by bending the end of the vent valve lever up or down until the specified gap (.030") is set. (5) Install vent valve lever spring and bowl vent cover plate. NOTE: THE BOWL VENT VALVE ADJUSTMENT MUST BE RESET IF THE ACCELERATOR PUMP ADJUSTMENT IS CHANGED. Publication #81-370-6007 TSB 14-04-87 May 4, 1987 Publication #81-370-6007 Page 14-51 7. BOWL VENT VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate and vent valve lever spring. CAUTION: Do not dislodge or misplace vent valve lever retainer/pivot pin. (2) With the throttle in the curb idle position, press firmly down on the vent valve lever where the spring seats; with another finger of the same hand, simultaneously press down on the vent valve tang until the vent valve is lightly seated (closed). CAUTION: If the carburetor is not on the engine, it must be on a raised fixture so as not to change the curb idle throttle plate position. (3) Using the other hand, measure the resulting gap between the contact surfaces of the vent valve lever and the vent valve tang with an appropriate gauge. (4) Adjust by bending the end of the vent valve lever up or down until the specified gap (.030") is set. (5) Install vent valve lever spring and bowl vent cover plate. NOTE: THE BOWL VENT VALVE ADJUSTMENT MUST BE RESET IF THE ACCELERATOR PUMP ADJUSTMENT IS CHANGED. Publication #81-370-6008 TSB 14-04-87 May 4, 1987 Publication #81-370-6008 Page 14-50 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Float Bowl Air Vent Valve > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2441 7. BOWL VENT VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate and vent valve lever spring. CAUTION: Do not dislodge or misplace vent valve lever retainer/pivot pin. (2) With the throttle in the curb idle position, press firmly down on the vent valve lever where the spring seats; with another finger of the same hand, simultaneously press down on the vent valve tang until the vent valve is lightly seated (closed). CAUTION: If the carburetor is not on the engine, it must be on a raised fixture so as not to change the curb idle throttle plate position. (3) Using the other hand, measure the resulting gap between the contact surfaces of the vent valve lever and the vent valve tang with an appropriate gauge. (4) Adjust by bending the end of the vent valve lever up or down until the specified gap (.030") is set. (5) Install vent valve lever spring and bowl vent cover plate. NOTE: THE BOWL VENT VALVE ADJUSTMENT MUST BE RESET IF THE ACCELERATOR PUMP ADJUSTMENT IS CHANGED. Publication #81-370-7007 TSB 14-04-87 May 4, 1987 Publication #81-370-7007 Page 14-58 8. BOWL VENT VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate and vent valve lever spring. CAUTION: Do not dislodge or misplace vent valve lever retainer/pivot pin. (2) With the throttle in the curb idle position, press firmly down on the vent valve lever where the spring seats; with another finger of the same hand, simultaneously press down on the vent valve tang until the vent valve is lightly seated (closed). CAUTION: If the carburetor is not on the engine, it must be on a raised fixture so as not to change. the curb idle throttle plate position. (3) Using the other hand, measure the resulting gap between the contact surfaces of the vent valve lever and the vent valve tang with an appropriate gauge. (4) Adjust by bending the end of the vent valve lever up or down until the specified gap (.030") is set. (5) Install vent valve lever spring and bowl vent cover plate. NOTE: THE BOWL VENT VALVE ADJUSTMENT MUST BE RESET IF THE ACCELERATOR PUMP ADJUSTMENT IS CHANGED. Publication #81-370-7008 TSB 14-04-87 May 4, 1987 Publication #81-370-7008 Page 14-60 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Float Bowl Air Vent Valve > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2442 8. BOWL VENT VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate and vent valve lever spring. CAUTION: Do not dislodge or misplace vent valve lever retainer/pivot pin. (2) With the throttle in the curb idle position, press firmly down on the vent valve lever where the spring seats; with another finger of the same hand, simultaneously press down on the vent valve tang until the vent valve is lightly seated (closed). CAUTION: If the carburetor is not on the engine, it must be on a raised fixture so as not to change the curb idle throttle plate position. (3) Using the other hand, measure the resulting gap between the contact surfaces of the vent valve lever and the vent valve tang with an appropriate gauge. (4) Adjust by bending the end of the vent valve lever up or down until the specified gap (.030") is set. (5) Install vent valve lever spring and bowl vent cover plate. NOTE: THE BOWL VENT VALVE ADJUSTMENT MUST BE RESET IF THE ACCELERATOR PUMP ADJUSTMENT IS CHANGED. Publication #81-270-7001 TSB 14-04-87 May 4, 1987 Publication #81-270-7001 Page 14-21 8. BOWL VENT VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate and vent valve lever spring. CAUTION: Do not dislodge or misplace vent valve lever retainer/pivot pin. (2) With the throttle in the curb idle position, press firmly down on the vent valve lever where the spring seats; with another finger of the same hand, simultaneously press down on the vent valve tang until the vent valve is lightly seated (closed). CAUTION: If the carburetor is not on the engine, it must be on a raised fixture so as not to change, the curb idle throttle plate position. (3) Using the other hand, measure the resulting gap between the contact surfaces of the vent valve lever and the vent valve tang with an appropriate gauge. (4) Adjust by bending the end of the vent valve lever, up or down until the specified gap (.030") is set. (5) Install vent valve lever spring and bowl vent cover plate. NOTE: THE BOWL VENT VALVE ADJUSTMENT MUST BE RESET IF THE ACCELERATOR PUMP ADJUSTMENT IS CHANGED. Publication #81-270-5001 TSB 14-04-87 May 4, 1987 Publication #81-270-5001 (3) Return to idle then reposition the adjusting screw on to the second highest step of the fast idle cam to verify fast idle speed. Readjust if necessary. (4) Return to idle and turn the engine off. Unplug and reconnect the vacuum hoses at the EGR valve and canister. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Float Bowl Air Vent Valve > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2443 (5) Reinstall the air cleaner and unplug and reconnect the vacuum hose from the carburetor to the heated air temperature sensor on the air cleaner. Remove the tachometer and reinstall the PCV valve. Idle speeds with the engine in normal operating condition (everything connected) may vary from set speeds. DO NOT READJUST. 11. CONCEALMENT PLUG REMOVAL (1) Remove air cleaner. (2) Disconnect all hoses from front of carburetor base. (3) Center punch at a point 1/4 inch from end of mixture screw housing. (4) Drill through at punch mark with 3/6 inch drill bit. (5) Repeat operation on opposite side. (6) Pry out plugs and save for reuse. (7) Reinstall hoses and air cleaner. BOWL VENT VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate and vent valve lever spring. CAUTION: Do not dislodge or misplace vent valve lever retainer/pivot pin. (2) With the throttle in the curb idle position, press firmly down on the vent valve lever where the spring seats; with another finger of the same hand, simultaneously press down on the vent valve tang until the vent valve is lightly seated(closed). CAUTION: If the carburetor is not on the engine, it must be on a raised fixture so as not to change the curb idle throttle plate position. (3) Using the other hand, measure the resulting gap between the contact surfaces of the vent valve lever and the vent valve tang with an appropriate gauge. (4) Adjust by bending the end of the vent valve lever up or down until the specified gap (.030") is set. (5) Install vent valve lever spring and bowl vent cover plate. NOTE: THE BOWL VENT VALVE ADJUSTMENT MUST, BE RESET IF THE ACCELERATOR PUMP ADJUSTMENT IS CHANGED. Publication #81-270-6001 TSB 14-04-87 May 4, 1987 Publication #81-270-6001 filling the fuel bowl with clean fuel, using another accelerator pump plunger assembly. Hold the discharge check ball and weight down with a small brass rod and operate the pump plunger by hand. If the check ball and seat are leaking, no resistance will be experienced when operating the plunger (Fig. 16). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Float Bowl Air Vent Valve > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2444 If the valve is leaking, remove weight and stake the ball using a suitable drift punch. Exercise care when staking the ball to avoid damaging the bore containing the pump weight. After staking with the old ball, remove and replace with new ball from tuneup kit. Install weight and re-check for leaks. (4) Install new gaskets on venturi cluster, then install cluster in position in main body (Fig. 13). Install cluster screws and tighten securely. (5) Install main metering jets (Fig. 11). (6) Install vacuum and mechanical power valves (2280 models only) using Special Tool C-4231 (Fig. 12). Be careful not to damage power valve needles. CAUTION: Be sure the Power Valves are installed in their proper location, Mechanical Valve on choke side and Vacuum Valve on Throttle Lever Side. (7) A nitrophyl float can be checked for fuel absorption by lightly squeezing between fingers. If wetness appears on surface or float feels heavy (check with known good float), replace the float assembly. (8) Install hinge pin in float assembly. Insert hinge through slot in float baffle with tabs on baffle pointing downward. Position assembly in hinge pin cradle in carburetor main body (Fig. 10). (9) Place a new gasket on fuel inlet fitting and install assembly into main body, tighten securely to 180 inch pounds (20 N-m). Check float level. Refer to carburetor adjustments for adjusting procedure. (10) Install feedback solenoid on 6280 models. FIGURE 17 - SERVICING VACUUM POWER VALVE PISTON AND RETAINING RING Air Horn (1) Test freeness of choke mechanism in air horn. The choke shaft must float free to operate correctly. If choke sticks in bearing bores, or appears to be gummed from deposits in air horn, a thorough cleaning will be required. (2) Before installing the vacuum power valve assembly in bowl cover, be sure and remove all staking from the retainer cavity. Install the spring and piston in the vacuum cylinder, seat the retainer and stake lightly with suitable tool (Fig. 17). Compress piston to be sure no binding exists. If piston sticks or binds enough to hinder smooth operation, a new piston should be installed. FIGURE 18 - SERVICING MECHANICAL POWER VALVE PUSH ROD (3) Install mechanical power valve push rod spring, push rod and "E" clip retainer. Push plastic cap on to push rod (2280 models only) (Fig. 18). (4) Install accelerator pump plunger assembly through air horn and attach internal lever with C-link (2280 models only). On 6280 models, install new accelerator pump cup. (5) Place a new gasket on air horn. Lower air horn straight down on main body; guiding accelerator pump plunger into its cylinder. Do not cut lip of Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Float Bowl Air Vent Valve > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2445 plunger on sharp edge of cylinder. Install attaching screws and tighten to 25 inch pounds from center out. TSB 14-04-87 May 4, 1987 Publication #81-270-6001 (6) Install accelerator pump arm, internal pump lever and pump operating shaft. On 2280 C link and internal pump lever must be attached to accelerator pump shaft. Install "E" clip (Fig. 5). (7) To install fast idle connector link, engage plain end in slot of fast idle cam (from inside). Engage other end of rod in choke lever. With choke valve wide open, slide lever over choke shaft; (aligning flats). Install attaching lockwasher and nut. Tighten securely (Fig. 3). (8) Install accelerator pump link in No. 1 hole closest to Air Horn and retain with cotter pin on throttle lever end. (9) Engage choke diaphragm link in slot in choke lever. Install choke diaphragm assembly and secure with attaching screws (Fig. 2). Reinstall Vacuum Hose to Main Body. (10) Install bowl vent assembly (Fig. 1). (11) With pump links and levers installed, adjust the throttle blades to the closed position by backing out the idle speed screw. (12) Set the distance from the top of pump lever to the top of bowl vent cover surface to .050 +/.005 for 2280 models or .180 +/- .010 for 6280 models by bending the pump link. Check that wide open throttle can be reached without binding. (13) Install gasket and bowl vent cover plate. (14) Install Idle Stop Solenoid. (15) Install air cleaner bolt and retainer assembly. (16) Remove carburetor from repair stand. Choke Vacuum Kick The choke diaphragm adjustment controls the fuel delivery while the engine is running. It positions the choke valve within the air horn by action of the linkage between the choke shaft and the diaphragm. The diaphragm must be actuated to measure the vacuum kick adjustment. Vacuum can be supplied by an auxiliary vacuum source. Choke Unloader (Wide Open Kick) The choke unloader is a mechanical device to partially open the choke valve at wide open throttle. It is used to eliminate choke enrichment during cranking of an engine. Engines which have been flooded or stalled by excessive choke enrichment can be cleared by use of the unloader. Refer to carburetor adjustments for adjusting procedure. Fast Idle Speed Fast idle engine speed is used to overcome cold engine friction, stalls after cold starts and stalls because of carburetor icing. Refer to carburetor adjustments for procedure. Fast Idle Cam Position This adjustment is used to provide cam stop speeds at proper times during engine warmup. TSB 14-04-87 May 4, 1987 Publication #81-270-6001 5. MECHANICAL POWER VALVE ADJUSTMENT (2280 MODELS ONLY) (1) Remove bowl vent cover plate. (2) Hold throttle in wide open position. (3) Insert 5/64" Allen wrench in mechanical power valve adjustment screw. (4) Push screw down and release to determine if clearance exists. Turn screw clockwise until clearance is zero. (5) Adjust by turning screw counter clockwise one turn. (6) Install bowl vent gasket and cover plate. IF ACCELERATOR PUMP ADJUSTMENT IS CHANGED, THIS ADJUSTMENT MUST BE RESET. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Float Bowl Air Vent Valve > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2446 6. ACCELERATOR PUMP STROKE MEASUREMENT 6280 MODELS (1) Remove bowl vent cover plate and gasket. (2) With pump links and levers installed, adjust the throttle blades to the closed position by backing out the idle speed screw. (3) Set the distance from the top of pump lever to the top of bowl vent cover surface to .180 +/.010" by bending the pump link. Check that wide open throttle can be reached without binding. (4) Install gasket and bowl vent cover plate. (5) Reset Idle Speed. TSB 14-04-87 May 4, 1987 Publication #81-270-6001 7. ACCELERATOR PUMP STROKE MEASUREMENT 2280 MODELS (1) Remove bowl vent cover plate and vent valve lever and spring. Caution. Do not dislodge or lose vent valve lever retainer. (2) With pump link in No. 1 inner hole and levers installed, adjust the throttle blades to the closed position by backing out the idle speed screw. (3) Set the distance from the top of pump lever to the top of bowl vent cover surface to .050" +/.005" by bending the pump link. Check that wide open throttle can be reached without binding. (4) Install vent valve lever and spring and gasket and bowl vent cover plate. (5) Reset Idle Speed. NOTE: IF THIS ADJUSTMENT IS CHANGED, BOTH THE BOWL VENT AND THE MECHANICAL POWER VALVE ADJUSTMENTS MUST BE RESET. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Float Bowl Air Vent Valve > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2447 8. IDLE RPM ADJUSTMENT (2280 MODELS) Before checking or adjusting any idle speed, check ignition timing and adjust if necessary using the procedure shown in Group 8 Electrical. Disconnect and plug the vacuum hose at the EGR valve. Also disconnect and plug the vacuum hose from the carburetor at the heated air temperature sensor. Remove the air cleaner and disconnect and plug the 3/16 inch diameter control hose at the canister. Remove the PCV valve from the cylinder head cover and allow the valve to draw underhood air. Disconnect and plug vacuum hose at ESA module. Install tachometer. Start and run engine until normal operating temperature is reached. RPM Chrysler No. Vendor No. Refer to VECI Label 4288581 R-40245A On a new vehicle (under 300 miles/500 km), reduce RPM settings by 75 RPM. (1) Allow the engine to run for one minute for the engine speed to stabilize. (2) If the engine rpm is not correct, turn the idle speed screw to obtain the correct idle rpm. (3) Turn off engine. Unplug and reconnect vacuum hoses at EGR valve, canister, and ESA Module. (4) Reinstall air cleaner and unplug and reconnect vacuum hose from carburetor to heated air temperature sensor on air cleaner. Remove tachometer and reinstall PCV valve. Idle speeds with the engine in normal operating condition (all hoses and wires connected) may vary from set speeds. DO NOT READJUST. TSB 14-04-87 May 4, 1987 Publication #81-270-6001 (6) Return to idle and turn the engine off. Unplug and reconnect the vacuum hoses at the EGR valve and canister. Remove jumper wire. (7) Model 6280 only-separate carburetor electrical connector from engine wire harness. Reinstall the green and blue wires in their correct positions. Reconnect to the engine wire harness. (8) Reinstall the air cleaner and unplug and reconnect the vacuum hose from the carburetor to the heated air temperature sensor on the air cleaner. Remove the tachometer and reinstall the PCV valve. Idle speeds with the engine in normal operating condition (everything connected) may vary from set speeds. DO NOT READJUST. 11. CONCEALMENT PLUG REMOVAL Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Float Bowl Air Vent Valve > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2448 (1) Remove air cleaner. (2) Disconnect all hoses from front of carburetor base. (3) Center punch at a point 1/4 inch from end of mixture screw housing. (4) Drill through at punch mark with 3/16 inch drill bit. (5) Repeat operation on opposite side. (6) Pry out plugs and save for reuse. (7) Reinstall hoses and air cleaner. BOWL VENT VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate and vent valve lever spring. CAUTION: Do not dislodge or misplace vent valve lever retainer/pivot pin. (2) With the throttle in the curb idle position, press firmly down on the vent valve lever where the spring seats; with another finger of the same hand, simultaneously press down on the vent valve tang until the vent valve is lightly seated (closed). CAUTION: If the carburetor is not on the engine, it must be on a raised fixture so as not to change, the curb idle throttle plate position. (3) Using the other hand, measure the resulting gap between the contact surfaces of the vent valve lever and the vent valve tang with an appropriate gauge. (4) Adjust by bending the end of the vent valve lever up or down until the specified gap (.030") is set. (5) Install vent valve lever spring and bowl vent cover plate. NOTE: THE BOWL VENT VALVE ADJUSTMENT MUST BE RESET IF THE ACCELERATOR PUMP ADJUSTMENT IS CHANGED. Publication #81-370-6007 FIGURE 16 - SERVICING VACUUM POWER VALVE PISTON AND RETAINING RING TSB 14-04-87 May 4, 1987 Publication #81-370-6007 tween fingers. If wetness appears on surface or float feels heavy (check with known good float), replace the float assembly. (8) Place a new gasket on fuel inlet fitting and install assembly into main body, tighten securely. Check float level. Refer to carburetor adjustments for adjusting procedure. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Float Bowl Air Vent Valve > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2449 FIGURE 17 - SERVICING MECHANICAL POWER VALVE PUSH ROD Air Horn (1) Test freeness of choke mechanism in air horn. The choke shaft must float free to operate correctly. If choke sticks in bearing bores, or appears to be gummed from deposits in air horn, a thorough cleaning will be required. (2) Install vacuum power piston spring and piston in its cylinder, Place retaining ring over piston stem and carefully seat in place (Fig. 7). Compress piston to be sure no binding exists. If piston sticks or binds enough to hinder smooth operation, a new piston should be installed. (3) Install mechanical power valve push rod spring, push rod and "E" clip retainer. Push plastic cap on to push rod (2280 models only) (Fig. 17). (4) Install accelerator pump plunger assembly through air horn and attach internal lever with C-link (2280 models only). On 6280 models, install new accelerator pump cup. (5) Place a new gasket on air horn. Lower air horn straight down on main body; guiding accelerator pump plunger into its cylinder. Do not cut lip of plunger on sharp edge of cylinder. Install attaching screws and tighten to 25 inch pounds from center out. (6) Install accelerator pump arm, internal pump lever and pump operating shaft. On 2280 C-link and internal pump lever must be attached to accelerator pump shaft. Install "E" clip (Fig. 5). (7) To install fast idle connector link, engage plain end in slot of fast idle cam (from inside). Engage other end of rod in choke lever. With choke valve wide open, slide lever over choke shaft; (aligning flats). Install attaching lockwasher and nut. Tighten securely (Fig. 3). (8) Install accelerator pump link in No. 1 hole closest to Air Horn and retain with cotter pin on throttle lever end. (9) Engage choke diaphragm link in slot in choke lever. Install choke diaphragm assembly and secure with attaching screw (Fig. 2) Reinstall Vacuum Hose to Main Body. (10) Install bowl vent assembly (Fig. 1). (11) With pump links and levers installed, adjust the throttle blades to the closed position by backing out the idle speed screw. (12) Set the distance from the top of pump lever to the top of bowl vent cover surface to .050 +/.005 for 2280 models or .180" +/- .010" from 6280 models by bending the pump link. Check that wide open throttle can be reached without binding. (13) Install gasket and bowl vent cover plate. (14) Install Idle Stop Solenoid. (15) Install air cleaner bolt and retainer assembly. (16) Remove carburetor from repair stand. TSB 14-04-87 May 4, 1987 Publication #81-370-6007 Choke Vacuum Kick The choice diaphragm adjustment controls the fuel delivery while the engine is running. It positions the choke valve within the air horn by action of the linkage between the choke shaft and the diaphragm. The diaphragm must be energized to measure the vacuum kick adjustment. Vacuum can be supplied by an auxiliary vacuum source. Choke Unloader (Wide Open Kick) The choke unloader is a mechanical device to partially open the choke valve at wide open throttle. It is used to eliminate choke enrichment during cranking of an engine. Engines which have been flooded or stalled by excessive choke enrichment can be cleared by use of the unloader. Refer to carburetor adjustments for adjusting procedure. Fast Idle Speed Fast idle engine speed is used to overcome cold engine friction, stalls after cold starts and stalls because of carburetor icing. Refer to carburetor adjustments for procedure. Fast Idle Cam Position This adjustment is used to provide cam stop speeds at proper times during engine warmup. TSB 14-04-87 May 4, 1987 Publication #81-370-6007 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Float Bowl Air Vent Valve > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2450 5. MECHANICAL POWER VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate. (2) Hold throttle in wide open position, (3) Insert 5/64" Allen wrench in mechanical power valve adjustment screw. (4) Push screw down and release to determine if clearance exists. Turn screw clockwise until clearance is zero. (5) Adjust by turning screw counter clockwise one turn. (6) Install bowl vent gasket and cover plate. IF ACCELERATOR PUMP ADJUSTMENT IS CHANGED, THIS ADJUSTMENT MUST BE RESET. 6. ACCELERATOR PUMP STROKE MEASUREMENT 6280 MODELS (1) Remove bowl vent cover plate and gasket. (2) With pump link and levers installed, adjust the throttle blades to the closed position by backing out the idle speed screw. (3) Set the distance from the top of pump lever to the top of bowl vent cover surface to .180" +/.010" by bending the pump link. Check that wide open throttle can be reached without binding. (4) Install gasket and bowl vent cover plate. (5) Reset Idle Speed. TSB 14-04-87 May 4, 1987 Publication #81-370-6007 12. PROPANE ASSISTED IDLE SET PROCEDURE (2280 AND 6280 MODELS) RPM Chrysler No. Vendor No. 4324629 R-40214A Refer to VECI Label 4324631 R-40216A 4324632 R-40221A 4324633 R-40222A On a new vehicle (under 300 miles/500km) reduce RPM settings by 75 RPM. Tampering with the carburetor is a violation of Federal law. Adjustment of the carburetor idle air fuel mixture can only be done under certain circumstances as explained below. Upon completion of the adjustment, the concealment plugs must be replaced. This procedure should only be used if an idle defect still exists after normal diagnosis reveals Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Float Bowl Air Vent Valve > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2451 no other faulty condition such as incorrect basis timing, incorrect idle speed, faulty hose or wiring connections, etc. Adjustment of the carburetor air fuel mixture should be performed after a major carburetor overhaul. (1) Remove the concealment plug. Set the parking brake and place the transmission in neutral. Turn all lights and accessories off. Connect a tachometer to the engine. Start the engine and allow it to warm up on the second highest step of the fast idle cam until normal operating temperature is reached return the engine to idle and turn off engine. (2) Remove air cleaner, disconnect and plug the vacuum hoses at the EGR valve and ESA computer. No vacuum is to be applied to the computer. Disconnect and plug canister purge hose at canister. (3) Disconnect carburetor electrical connector. (4) Remove the PCV valve from the cylinder head and allow the valve to draw underhood air. (5) Start and run engine. (6) Disconnect the vacuum supply hose from the choke diaphragm at the carburetor and install the propane supply hose in its place. Other connections at the tee must remain in place. (7) With the propane bottle upright and in a safe location, open the propane main valve. Slowly open the propane metering valve until the maximum engine rpm is reached. When too much propane is added, engine rpm will decrease. "Fine tune" the metering valve to obtain the highest engine rpm. (8) With the propane still flowing, adjust the idle speed screw on the solenoid to obtain the correct propane rpm. Again, "fine tune" the metering valve to obtain the highest engine rpm. If there has been a change in the maximum rpm, readjust the idle speed screw to the specified propane rpm. (9) Turn off the propane main valve and allow the engine speed to stabilize. Slowly adjust the mixture screws by equal amounts, pausing between adjustments to allow engine speed to stabilize, to obtain the smoothest idle at the correct idle rpm. (10) Turn on the propane main valve end "Fine tune" the metering valve to obtain the highest engine rpm. If the maximum engine speed is more than 25 rpm different than the specified propane rpm, repeat steps (8) through (11). (11) Turn off propane main and metering valves. Remove the propane supply hose and reinstall the heated air sensor hose. Reinstall new concealment plugs. Reconnect vacuum line on ESA, reconnect carburetor electrical connector. Perform the Solenoid Idle Stop, Idle RPM, and Fast Idle Speed Adjustment Procedures. 13. ACCELERATOR PUMP STROKE MEASUREMENT 2280 MODELS (1) Remove bowl vent cover plate and vent valve lever/and spring. Caution: Do not dislodge or lose vent valve lever retainer. (2) With pump link in No.1 inner hole and levers installed, adjust the throttle blades to the closed position by backing out the idle speed screw. (3) Set the distance from the top of pump lever to the top of bowl vent cover surface to .050" +/.005" by bending the pump link. Check that wide open throttle can be reached without binding. (4) Install vent valve lever and spring and gasket and bowl vent cover plate. (5) Reset Idle Speed. NOTE: IF THIS ADJUSTMENT IS CHANGED, BOTH THE BOWL VENT AND THE MECHANICAL POWER VALVE ADJUSTMENTS MUST BE RESET. Publication #81-370-6008 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Float Bowl Air Vent Valve > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2452 FIGURE 15 - TESTING ACCELERATOR PUMP DISCHARGE CHECK BALL AND SEAT FIGURE 16 - SERVICING VACUUM POWER VALVE PISTON AND RETAINING RING FIGURE 17 - SERVICING MECHANICAL POWER VALVE PUSH ROD Publication #81-370-6008 Revised TSB 14-04-87 May 4, 1987 (3) Install mechanical power valve push rod spring, push rod spring, push rod and "E" clip retainer. Push plastic cap on to push rod (2280 models only) (Fig. 8). (4) Install accelerator pump plunger assembly through air horn and attach internal lever with Clink (2280 models only). On 6280 models, install new accelerator pump cup. (5) Place a new gasket on air horn. Lower air horn straight down on main body; guiding accelerator pump plunger into its cylinder. Do not cut lip of plunger on sharp edge of cylinder. Install attaching screws and tighten to 25 inch pounds from center out. (6) Install accelerator pump arm, internal pump lever and pump operating shaft. On 2280 C link and internal pump lever must be attached to accelerator pump shaft. Install "E" clip (Fig. 5). (7) To install fast idle connector link, engage plain end in slot of fast idle cam (from inside). Engage other end of rod in choke lever. With choke valve wide open, slide lever over choke shaft; (aligning flats). Install attaching lockwasher and nut. Tighten securely (Fig. 3). (8) Install accelerator pump link in No. 1 hole closest to Air Horn and retain with cotter pin on throttle lever end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Float Bowl Air Vent Valve > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2453 (9) Engage choke diaphragm link in slot in choke lever. Install choke diaphragm assembly and secure with attaching screw (Fig. 2) Reinstall Vacuum Hose to Main Body. (10) Install bowl vent assembly (Fig. 1). (11) With pump links and levers installed, adjust the throttle blades to the closed position by backing out the idle speed screw. (12) Set the distance from the top of pump lever to the top of bowl vent cover surface to .050 +/.005 for 2280 models or .180" +/- .010" for 6280 models by bending the pump link. Check that wide open throttle can be reached without binding. (13) Install gasket and bowl vent cover plate. (14) Install Idle Stop Solenoid. (15) Install air cleaner bolt and retainer assembly. (16) Remove carburetor from repair stand. TSB 14-04-87 May 4, 1987 Publication #81-370-6008 5. MECHANICAL POWER VALVE ADJUSTMENT 2280 (1) Remove bowl vent cover plate. (2) Hold throttle in wide open position. (3) Insert 5/64" Allen wrench in mechanical power valve adjustment screw. (4) Push screw down and release to determine if clearance exists. Turn screw clockwise until clearance is zero. (5) Adjust by turning screw counter clockwise one turn. (6) Install bowl vent gasket and cover plate. If accelerator pump adjustment is changed, this adjustment must be reset. 6. ACCELERATOR PUMP STROKE MEASUREMENT (AT IDLE) 6280 (1) Remove bowl vent cover plate and gasket. (2) With pump link and levers installed, adjust the throttle blades to the closed position by backing out the idle speed screw. (3) Set the distance from the top of pump lever to the top of bowl vent cover surface to .180 +/.010" by bending the pump link. Check that wide open throttle can be reached without binding. (4) Install gasket and bowl vent cover plate. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Float Bowl Air Vent Valve > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2454 (5) Reset Idle Speed. TSB 14-04-87 May 4, 1987 Publication #81-370-6008 12. PROPANE ASSISTED IDLE SET PROCEDURE (2280 AND 6280 MODELS) RPM Chrysler No. Vendor No. 4324629 R-40214A Refer to 4324631 R-40216A VECI Label 4324632 R-40221A 4324633 R-40222A On a new vehicle (under 300 miles/500 km) reduce RPM settings by 75 RPM. Tampering with the carburetor is a violation of Federal law. Adjustment of the carburetor idle air fuel mixture can only be done under certain circumstances as explained below. Upon completion of the adjustment, the concealment plugs must be replaced. This procedure should only be used if an idle defect still exists after normal diagnosis reveals no other faulty condition such as incorrect basis timing, incorrect idle speed, faulty hose or wiring connections, etc. Adjustment of the carburetor air fuel mixture should be performed after a major carburetor overhaul. (1) Remove the concealment plug. Set the parking brake and place the transmission in neutral. Turn all lights and accessories off. Connect a tachometer to the engine. Start the engine and allow it to warm up on the second highest step of the fast idle cam until normal operating temperature is reached. Return the engine to idle and turn off engine. (2) Remove air cleaner, disconnect and plug the vacuum hoses at the EGR valve and ESA computer. No vacuum is to be applied to the computer. Disconnect and plug canister purge hose at canister. (3) Disconnect carburetor electrical connector. (4) Remove the PCV valve from the cylinder head cover and allow the valve to draw underhood air. (5) Start and run engine. (6) Disconnect the vacuum supply hose from the choke diaphragm at the carburetor and install the propane supply hose in its place. Other connections at the tee must remain in place. (7) With the propane bottle upright and in a safe location, open the propane main valve, Slowly open the propane metering valve until the maximum engine rpm is reached. When too much propane is added, engine rpm will decrease. "Fine tune" the metering valve to obtain the highest engine rpm. (8) With the propane still flowing, adjust the idle speed screw on the solenoid to obtain the correct propane rpm. Again, "fine tune" the metering valve to obtain the highest engine rpm. If there has been a change in the maximum rpm, readjust the idle speed screw to the specified propane rpm. (9) Turn off the propane main valve and allow the engine speed to stabilize. Slowly adjust the mixture screws by equal amounts, pausing between adjustments to allow engine speed to stabilize, to obtain the smoothest idle at the correct idle rpm. (10) Turn on the propane main valve and "Fine tune" the metering valve to obtain the highest engine rpm. If the maximum engine speed is more than 25 rpm different than the specified propane rpm, repeat steps 8 through 12. (11) Turn off propane main and metering valves. Remove the propane supply hose and reinstall the heated air sensor hose. Reinstall new concealment plugs. Reconnect vacuum line on ESA, reconnect carburetor electrical connector. Perform the Solenoid Idle Stop, Idle RPM, and Fast Idle Speed Adjustment Procedures. 13. ACCELERATOR PUMP STROKE MEASUREMENT 2280 MODELS (1) Remove bowl vent cover plate and vent valve lever/and spring. Caution: Do not dislodge or lose vent valve lever retainer. (2) With pump link in No. 1 inner hole and levers installed, adjust the throttle blades to the closed position by backing out the idle speed screw. (3) Set the distance from the top of pump lever to the top of bowl vent cover surface to .050" +/.005" by bending the pump link. Check that wide open throttle can be reached without binding. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Float Bowl Air Vent Valve > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2455 (4) Install vent valve lever and spring and gasket and bowl vent cover plate. (5) Reset Idle Speed. NOTE: IF THIS ADJUSTMENT IS CHANGED, BOTH THE BOWL VENT AND THE MECHANICAL POWER VALVE ADJUSTMENTS MUST BE RESET. Publication #81-370-6010 TSB 14-04-87 May 4, 1987 Publication #81-370-6010 5. ACCELERATOR PUMP STROKE MEASUREMENT 6280 MODELS (1) Remove bowl vent cover plate and gasket. (2) With pump links and levers installed, adjust the throttle blades to the closed position by backing out the idle speed screw. (3) Set the distance from the top of pump lever to the top of bowl vent cover surface to .180" +/.010" by bending the pump link. Check that wide open throttle can be reached without binding. (4) Install gasket and bowl vent cover plate. (5) Reset Idle Speed. 6. IDLE SPEED ADJUSTMENT Before checking or adjusting any idle speed, check ignition timing and adjust if necessary using the procedure shown in Group 8 Electrical. Disconnect and plug the vacuum hose at the EGR valve and air switching valve. Also disconnect and plug the vacuum hose from the carburetor at the heated air temperature sensor. Remove the air cleaner and disconnect and plug the 3/16 inch diameter control hose at the canister. Remove the PCV valve from the cylinder head cover and allow the valve to draw underhood air. Install tachometer. Start and run engine until normal operating temperature is reached. RPM Refer to VECI Label (1) Allow the engine to run for one minute for the engine speed to stabilize. (2) If the engine rpm is not correct, turn the idle speed screw to obtain the correct idle rpm. (3) Turn off engine. Unplug and reconnect vacuum hoses at EGR valve, canister, and air switching valve. (4) Reinstall air cleaner and unplug and reconnect vacuum hose from carburetor to heated air temperature sensor on air cleaner. Remove tachometer Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Float Bowl Air Vent Valve > Component Information > Technical Service Bulletins > Carburetor Adjustments - Manual Revisions > Page 2456 and reinstall PCV valve. Idle speeds with the engine in normal operating condition (all hoses and wires connected) may vary from set speeds. DO NOT READJUST. Publication #81-370-7010 TSB 14-04-87 May 4, 1987 Publication #81-370-7010 5. ACCELERATOR PUMP STROKE MEASUREMENT (1) Remove bowl vent cover plate and gasket. (2) With pump links and levers installed, adjust the throttle blades to the closed position by backing out the idle speed screw. (3) Set the distance from the top of pump lever to the top of bowl vent cover surface to .180" +/.010" by bending the pump link. Check that wide open throttle can be reached without binding. (4) Install gasket and bowl vent cover plate. (5) Reset Idle Speed. 6. IDLE RPM ADJUSTMENT Before checking or adjusting any idle rpm, check ignition and adjust, if necessary, using procedure in Group 8, Electrical. Ground the carburetor switch on vacuum kicker with jumper wire. Disconnect and plug the vacuum hose at the air switching valve, Disconnect and plug the 3/16 in. diameter canister purge control hose at the solenoid. Remove the PCV valve from the cylinder head cover and allow the valve to draw underhood air. Install tachometer. Start and run engine until normal operating temperature is reached. RPM Refer to VECI Label (1) Allow the engine to run for one minute for the engine speed to stabilize. (2) If the engine rpm is not correct, turn the idle speed screw to obtain the correct idle rpm. (3) Turn off engine. Unplug and reconnect vacuum hoses at canister, and air switching valve. (4) Remove tachometer and reinstall PCV valve. Idle speeds with the engine In normal operating condition (all hoses and wires connected) may vary from set speeds. DO NOT READJUST. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - Alcohol Fuel Recommendations Fuel: Technical Service Bulletins Fuel - Alcohol Fuel Recommendations Models All Gasoline Fueled Subject Alcohol Blend Fuels Index FUEL Date October 22, 1984 No.. 14-52-84 P-4644-C The increasing availability of gasolines containing alcohol has resulted in the need to provide additional information relative to driveability problems that may be experienced with the use of gasolines containing alcohol. Chrysler's 1984 and 1985 Owner's Manual statement on gasolines containing alcohol reads as follows: Gasolines Containing Alcohol Some gasolines sold at service stations contain alcohol, although they may not be so identified. Use of fuels containing alcohol is not recommended, unless the nature of the blend can be determined as being satisfactory. Gasohol - A mixture of 10% Ethanol (grain alcohol) and 90% unleaded gasoline may be used in your vehicle. If driveability problems are experienced as a result of using gasohol, it is recommended that the vehicle be operated on gasoline. Methanol - Do not use gasolines containing Methanol (wood alcohol). Use of this type of alcohol can result in vehicle performance deterioration and damage critical parts in the fuel pump, carburetor, and other fuel system components. Fuel system damage and vehicle performance problems, resulting from the use of gasolines containing Methanol, may not be covered by the new vehicle warranty. The following comments do not appear in the owners manuals. Although gasohol is not recommended, it may be used. However, driveability problems may be experienced, such as longer starting times, hesitation/stumble on accelerations, and/or loss of power on accelerations resulting from fuel foaming/vapor lock due primarily to the increased volatility of the gasohol. For customer complaints of this nature, and if the customer is using gasohol or a fuel of unknown corn position, it is strongly recommended that the vehicle be returned to 100% unleaded gasoline to obtain maximum driveability, performance, and fuel economy. You can easily test the fuel for the presence and percentage of alcohol by using Miller Tool #C-4846. This special tool is listed in your Miller Tool Catalog. It is our recommendation that customers are made aware of the cautionary fuel statement in the Owner's Manual in order to avoid unnecessary driveability complaints. Customers may question the availability of alcohol-free fuel. As of the date this bulletin was printed 22 states will have passed alcohol labeling laws which require a label on the pump if alcohol is present in the gasoline. The attached is a partial list of where the major fuel suppliers stand on alcohol blended fuels. Discretionary use of alcohol blends by independent retailers, however, may occur and should be recognized. POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - Alcohol Fuel Recommendations > Page 2461 ALCOHOL BLENDS: WHERE THE MAJORS STAND COMPANY MARKET BLEND Amoco Iowa, Eastern Nebraska, Southeastern South 10% Ethanol Dakota and Kansas. Arco About 1,400 branded jobber and dealer outlets in Oxinol: 4.75% New York and Pennsylvania; wholesales to small Methanol, 4.57% refiners, unbranded distributors; owns a 200 Co-solvents million gallon a year methanol plant. Ashland Kentucky, Ohio, Michigan, Indiana, and Iowa; joint 10% Ethanol venture partner in a 60 gallon a year ethanol plant at Southpoint, Ohio. Chevron About 1,000 stations in Kentucky and Tennessee; 10% Ethanol 83% interest in a 21 million gallon a year Kentucky ethanol plant. Conoco Wholesales ethanol at terminals in Missouri, 10% Ethanol Illinois, Nebraska, and Kansas. Jobbers sell blends in Nebraska and Iowa and the company sells blends through its subsidiary, Western Stores in Iowa. Exxon None None Getty Three small regions in Omaha, Nebraska; 10% Ethanol Northeastern Iowa, and Western Kansas. Owns 100 million gallon a year methanol plant in Delaware (but not blending). Gulf Last year considered owning part of an None ethanol plant in North Carolina. Marathon None None Mobil None None Phillips Illinois, Indiana, Missouri, and Iowa. 10% Ethanol Shell None None Sohio None None COMPANY MARKET BLEND Southland Markets ethanol blends in 14 states, primarily 10% Ethanol, California, Florida, Illinois, Indiana, Iowa, Oxinol Kansas, New Mexico, Ohio, Tennessee, and Utah. Testing oxinol in Houston. Sun Test marketed oxinol at about 200 branded None stations in Pennsylvania. Tenneco Tennessee and Florida, owns a 135 million 10% Ethanol gallon a year methanol plant in Texas, but does not blend methanol. Texaco Illinois, Indiana, Kentucky, Western Tennessee, 10% Ethanol and St. Louis. Owns 50% of 60 million gallon a year ethanol plant in Illinois. Union None None Sources: Information Resources, Inc., Washington, D.C. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2470 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2471 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2472 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2473 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2474 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2475 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2476 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2477 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2478 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2479 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2480 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2481 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2482 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2483 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2484 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2490 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2491 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2492 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2493 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2494 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2495 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2496 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2497 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2498 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2499 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2500 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2501 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2502 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2503 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filter: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2504 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2513 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2514 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2515 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2516 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2517 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2518 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2519 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2520 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2521 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2522 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2523 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2524 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2525 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2526 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2527 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock Technical Service Bulletin # 181985A Date: 851201 Fuel System - Vapor Lock Models 1981-1985 Van & Wagon Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 20, 1985 No. 18-19-85 REVISION A P-4782-C This bulletin supersedes Technical Service Bulletin #18-19-85 which should be removed from your files. The model application has been expanded to include 1981 and 1982 model years. SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING TWO PART NUMBERS: Vapor Lock Package With 22 Gallon Fuel Tank PN 4397611 Vapor Lock Package With 36 Gallon Fuel Tank PN 4397612 ADDITIONAL PARTS INFORMATION ON NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 All vehicles equipped with dual air conditioning, without electrically heated rear window defroster, and with 60 amp alternator must order the following package in addition to the vapor lock package. If vehicle is equipped with a 114 amp alternator, do not order this package or make any changes to the charging system. 1 78 AMP Alternator Package PN 4397615 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2532 Refer to parts list for contents of each package. Must be ordered separately: 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. REPAIR PROCEDURE A.Engine Compartment Harness Pn 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1A - ENGINE COMPARTMENT WIRING 3. Remove engine cover. Install the bare eyelet terminal of overlay harness, PN 4362295, to the negative terminal of the ignition coil as shown in Figure 1-A. FIGURE 1B - ENGINE COMPARTMENT WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2533 4. Route and secure the engine overlay harness, PN 4362295, along the existing main engine wiring harness using the existing wiring clips and two tie wraps, PN 6015756 (Figure 1-B). FIGURE 1C - ENGINE COMPARTMENT WIRING 5. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness to the bulkhead connector using the existing wiring clips and three tie wraps, PN 6015756 (Figure 1-C). Loop and tape any excess wire of the engine overlay harness. FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 6. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar multi-purpose grease PN 4318063, and snap into cavity #14 of the engine side of the bulkhead connector (Figure 1-D). B.Instrument Panel Harnesses Pn 4362289, All Models Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2534 FIGURE 2A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) 1. Remove instrument panel left lower trim panel. 2. Insert two bare terminals from instrument panel overlay harness, PN 4362289, into the instrument panel side of the bulkhead connector (Figure 2-A). a. Gray with black tracer wire into cavity #14. b. Dark green wire into cavity #13. INSTRUMENT PANEL WIRING 3. Secure bare eyelet ground terminal (white with black tracer wire) from instrument panel overlay harness, PN 4362289, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). NOTE: CERTAIN VEHICLES ARE ALREADY EQUIPPED WITH THE GROUND SCREW. IF SO, DISCARD THE SUPPLIED SCREW. FIGURE 2C - INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2535 FIGURE 2D - INSTRUMENT PANEL WIRING 4. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-C). Install the extracted terminal (orange wire) into the natural colored 1-way connector supplied with instrument panel overlay harness, PN 4362289. Install the bare terminal (orange wire) from the instrument panel overlay harness, PN 4362289, into the vacated cavity in the ignition switch connector. Reconnect the natural colored 1-way connectors supplied with the instrument panel overlay harness, PN 4362289, and reconnect the ignition switch connectors (Figure 2-C and 2-D). FIGURE 2E - TYPICAL CONTROL MODULE MOUNTING 5. Connect the control (auto shut-down) module, PN 5226640, to the natural colored 8-way connector from instrument panel overlay harness, PN 4362289. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2536 FIGURE 2D - INSTRUMENT PANEL WIRING FIGURE 2F - INSTRUMENT PANEL WIRING 6. Route the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289, to the back of the brake bracket for mating in a later step (Figures 2-B, 2-D, and 2-F). Secure instrument panel overlay harness, PN 4362289, using tie wrap, PN 6015756, to keep it clear of any possible interferences. Only one of the following installation procedures (Step 7) will be used. Take notice of which one applies to the vehicle being repaired. 7. Without Auxiliary Air Conditioning and/or Heater - Jumper Harness PN 4362291 a. Remove instrument panel hood and bezel assembly and remove radio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2537 FIGURE 2D - INSTRUMENT PANEL WIRING b. Route instrument panel jumper harness, PN 4362291, from the back of the brake bracket to the existing 3-way red molded connector. Secure by using existing wiring clips (Figure 2-D). c. Insert the bare bullet terminal (black with white tracer wire) from instrument panel jumper harness, PN 4362291, into the existing 3-way red molded connector from the main instrument panel wiring harness (Figure 2-D). d. Mate the orange colored 1-way connector from instrument panel jumper harness, PN 4362291, to the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). e. Reinstall instrument panel hood and bezel assembly and install radio. FIGURE 2F - INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater and Power Windows - Jumper Harness PN 4362292 a. Disconnect from each other, the two existing brown colored 1-way connectors located near the left instrument panel vent (Figure 2-F). Reconnect these two brown colored 1-way connectors to the two brown colored 1-way connectors from instrument panel jumper harness, PN 4362292 (Figure 2-F). b. Mate the orange colored 1-way connector from the instrument panel jumper harness, PN 4362292, to the orange colored 1-way connector from instrument panel overlay harness, PN 4362289 (Figure 2-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2538 INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater Without Power Windows - Relay Harness PN 4362290 a. Remove instrument panel hood and bezel assembly. Remove radio. b. Install the ignition switch protection relay, PN 4162597, to the back of the brake bracket (mounting location shown in Figure 2-B) and attach instrument panel relay harness, PN 4362290, to relay. c. Secure bare eyelet ground terminal (white wire) from instrument panel relay harness, PN 4362290, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING d. Route the dark blue wire from the instrument panel relay harness, PN 4362290 to the existing 3-way red molded connector using existing wiring clips. Insert bullet terminal (dark blue wire) into red molded connector (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2539 INSTRUMENT PANEL WIRING e. Insert bare bullet terminal (red wire) from instrument panel relay harness, PN 4362290, into the existing 3-way yellow molded connector from the main instrument panel wiring harness (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING f. Mate the orange colored 1-way connector from instrument panel relay harness, PN 4362290, to the colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). g. Install the instrument panel left lower trim panel, instrument panel hood, bezel assembly and radio. C.In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Feed red and yellow molds of body wiring harness, PN 4362293, through slot in the crossmember. Remove existing screw for gauge unit ground. Install eyelet terminal of harness, PN 4362293 (and ground eyelet terminal of 36 gallon tank gauge/pump unit) and torque ground screw to 36 inch pounds. CAUTION: GROUND SCREW MUST BE TIGHTENED SECURELY TO OPERATE ELECTRIC PUMP AND GAUGE UNIT. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2540 FIGURE 3A - BODY WIRING FIGURE 3B - BODY WIRING Install red mold of body harness, PN 4362293, onto red stud of gauge/pump unit. Install yellow mold of harness, PN 4362293, onto black stud of gauge/pump unit (figure 3-a or 3-b). Install molded blade terminal of harness, PN 4362293, onto blade terminal of 22 gallon gauge unit only. NOTE: PREVIOUS GAUGE UNIT GROUND WILL NOT BE USED ON 22 GALLON GAUGE/PUMP UNIT. ON 36 GALLON GAUGE PUMP UNIT, THE GROUND WIRE ON HARNESS PN 4362293 WILL NOT BE USED. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. Set aside the rest of harness, PN 4362293, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. D.Body Wiring Harness Pn 4362293 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2541 FIGURE 3C - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2542 FIGURE 3-F - BODY WIRING 1. Vehicles With 36 Gallon Tank Route harness, PN 4362293, to the right (passenger) side of vehicle along the fuel line tubes and tie wrap (1). At right frame rail, route harness forward to next crossmember (Figures 3-C and 3-E). Tie wrap harness in three (3) places. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2543 FIGURE 3D - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2544 FIGURE 3-F - BODY WIRING Vehicles With 22 Gallon Tank Route harness, PN 4362293, along right frame rail following brake lines (Figures 3-D and 3-E). Tie wrap in two (2) places. NOTE: HARNESS MUST BE ABOVE SHOCK STRUT WITH EITHER 36 OR 22 GALLON TANK. 2. At crossmember, route harness to the left rail following existing brake lines and tie wrap in two (2) places. At left rail, route harness forward through access holes following existing brake lines. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2545 FIGURE 3-F - BODY WIRING NOTE: HARNESS SHOULD BE TIGHT IN THIS AREA THE WRAP IN FOUR (4) PLACES (FIGURE 3-E). 3. At engine compartment, route harness through existing speedometer cable clips to bulkhead connector. If excess wiring exists; loop, tie wrap (2), and install into existing clip (Figure 3-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2546 FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 4. Plug bare terminal of harness, PN 4362293, into cavity #13 of the bulkhead connector (Figure 1-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2547 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2548 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2549 FIGURE 9 - ELECTRIC FUEL PUMP WIRING DIAGRAMW/AUX A/C & HEATER-W/O POWER WINDOWS 5. For all vehicles except those which require a 78 amp alternator package: Reinstall instrument panel side, then engine compartment side of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURES 7, 8, OR 9 FOR OVERALL WIRING DIAGRAMS. E.Engine Compartment Fuel Reservoir/Filter Lnstallation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2550 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER 1. Using template, PN 4418011, mark and drill (from engine side of passenger side chassis rail) two (2) holes .290" diameter (L size drill) as shown in Figure 4-A. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2551 FIGURE 4B - Mounting Fuel Resevoir/Filter 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. NOTE: RUBBER SPLASH SHIELD MAY HAVE TO BE CUT OUT AROUND FUEL RESERVOIR. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube, PN 4306968 (Figure 4-B). 4. Install return hose assembly, PN 4418006, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end (Figure 4-B). 5. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 42O3576. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2552 FIGURE 4B - Mounting Fuel Resevoir/Filter 6. Install one 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the fuel pump outlet tube to the reservoir/filter inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). 7. Install the other 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 8. Tighten all hose clamps to 10 inch pounds. FIGURE 10 9. Type Authorized Modification Label, PN 4275086, as shown in Figure 10 and attach near VECI label. 10. For all models except 1981-1984 equipped with Carter Thermoquad 4BBL carburetor or dual air conditioning units without electrically Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2553 heated rear window defroster. Reconnect battery. Start the engine, and inspect the entire system for fuel leaks and proper wire and hose routing. 11. Reinstall engine cover. F.1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (Pn 4397 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6O22254, (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT, AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6O22254. THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2554 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference with nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose-to-regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. For all models except those equipped with dual air conditioning units, without electrically heated rear window defroster and with 60 amp alternator: 6. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 7. Reinstall engine cover. G.Vehicles Equipped With Dual Air Conditioning Units, Without Electrically Heated Rear Defroster, and With 60 Amp Alternator. I Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2555 HEADLAMP AND DASH WIRING ASSEMBLY 1. Disconnect the battery positive lead (single in-line connection) from the headlamp and dash wiring assembly (Figure 6-A). FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 2. Remove the following wires from the engine compartment side of the bulkhead connector (Figure 6-B). a. Red wire from cavity #39 (ammeter). b. Black wire from cavity #33 (ammeter). Cut off the terminals and wrap tape around each end of both wires to insure that shorting cannot occur. Then tape the wrapped wires back against the main harness. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2556 FIGURE 6-C - 78 AMP ALTERNATOR WIRING 3. Remove the alternator output wire (heavy gauge) from the 60 amp alternator (Figure 6-C). Cut the wire off leaving approximately three (3) inches of wire extending out of the main harness. Tape the end of the lead thoroughly. Then fold and tape the lead back against the main harness to prevent shorting. 4. Remove 60 amp alternator assembly and install 78 amp alternator assembly, PN 4111204, per the service manual alternator replacement procedure. HEADLAMP AND DASH WIRING ASSEMBLY Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2557 FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 5. Beginning at the bulkhead, route and connect the wiring assembly, PN 4362343, as shown in Figure 6-A. Use the existing clip for main harness and tie wrap with three (3) tie wraps, PN 6015756. Insert the two bare terminals from alternator overlay wiring harness, PN 4362343, as shown in Figure 6-B as follows: NOTE: THE 4362343 ALTERNATOR OVERLAY HARNESS WAS MANUFACTURED WITH THE RED AND BLACK WIRES REVERSED. THEREFORE, IT WILL BE NECESSARY TO INSTALL THE BLACK WIRE (LABELED RED) INTO CAVITY #39 (RED WIRE PREVIOUSLY REMOVED), AND THE RED WIRE (LABELED BLACK) INTO CAVITY #33 (BLACK WIRE PREVIOUSLY REMOVED). FAILURE TO REVERSE THESE TWO WIRES WILL RESULT IN THE AMMETER SHOWING THE OPPOSITE CHARGE INDICATION. a. Red wire into cavity #33 (ammeter) - (labeled as black wire). b. Black wire into cavity #39 (ammeter) - (labeled as red wire). 6. Install wiring assembly, PN 4362343, alternator output terminal to new 78 amp alternator. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2558 FIGURE 6A1 7. Connect the battery positive lead and the headlamp and dash wiring assembly lead to those of the alternator overlay wiring assembly, PN 4362343, as shown in circled view of Figure 6-A. 8. Reinstall instrument panel half, then engine compartment half of bulkhead connector and torque to 40 inch pounds. 9. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 10. Reinstall engine cover. POLICY: Reimbursable within the provisions of the warranty and repair manual. TIME ALLOWANCE: Labor Operation No. 14-70-17-94 - All 2.5 Hrs. Optional Equipment: 14-70-17-60 - Carter Thermoquad Carburetor 0.5 Hrs. 14-70-17-61 - With Auxiliary A/C - Without Elec. 0.7 Hrs. Rear Window Defroster 14-70-17-62 - Without Auxiliary A/C 0.3 Hrs. 14-70-17-63 - With Auxiliary A/C - Without 0.4 Hrs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2559 Power Windows FAILURE CODE: AM - Authorized Modification Part List VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 22 GALLON FUEL TANK PACKAGE PART NO. 4397611 QTY PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075432 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Seal - Fuel Tank Gauge 3404451 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 36 GALLON FUEL TANK PACKAGE PART NO. 4397612 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075436 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Gasket - Fuel Tank Sending Unit 4115209 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2560 *It may be necessary to order clamp separately on early released packages. PARTS LIST FUEL PRESSURE REGULATOR PACKAGE FOR 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO.4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 PARTS LIST 78 AMP ALTERNATOR PACKAGE FOR 1981-1985 B MODEL TRUCKS WITH 5.2L OR 5.9L ENGINES PACKAGE PART NO. 4397615 QTY. PART NAME PART NO. 1 78 AMP Alternator Assembly - Complete 4111204 1 Alternator Overlay Wiring Harness 4362343 4 Tie Wrap 6015756 1 Gasket - Bulkhead Connector 4055399 FIGURE 4B - Mounting Fuel Resevoir/Filter 1. Fuel Filter/ Reservoir - 4418012 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2561 2. Screw - Self Tapping - 6022777 (2 Req.) 3. Tube Assy - Fuel Pump to Reservoir - 4306968 4. Return Hose & Sleeve Assy - 4418006 5. Hose Clamps - 6500650 (2 Req.) - 1/4" 6. Hose-Fuel Pump Outlet to Reservoir Inlet - 4203576 7. Hose-Reservoir Outlet to Carburetor or Regulator Fuel Tube - 4203576 8. Hose Clamps - 6500651 (4 Req.) - 5/16" Included but not shown: 2 piece Convolute Tubing - 4279993 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1 SCREW & WASHER - 6022254 2 REGULATOR BRACKET - 4418010 3 REGULATOR - 4418OD9 4 TUBE - REGULATOR TO CARB - 4418008 5 TUBE - RESERVOIR HOSE TO REGULATOR - 4418014 6 SCREW (2 EA.) - REGULATOR TO BRACKET - 6033066 7 CLAMP (5116) - 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2567 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2568 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2569 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2570 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2571 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2572 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2573 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2574 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2575 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2576 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2577 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2578 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2579 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2580 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2581 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock Technical Service Bulletin # 181985A Date: 851201 Fuel System - Vapor Lock Models 1981-1985 Van & Wagon Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 20, 1985 No. 18-19-85 REVISION A P-4782-C This bulletin supersedes Technical Service Bulletin #18-19-85 which should be removed from your files. The model application has been expanded to include 1981 and 1982 model years. SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING TWO PART NUMBERS: Vapor Lock Package With 22 Gallon Fuel Tank PN 4397611 Vapor Lock Package With 36 Gallon Fuel Tank PN 4397612 ADDITIONAL PARTS INFORMATION ON NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 All vehicles equipped with dual air conditioning, without electrically heated rear window defroster, and with 60 amp alternator must order the following package in addition to the vapor lock package. If vehicle is equipped with a 114 amp alternator, do not order this package or make any changes to the charging system. 1 78 AMP Alternator Package PN 4397615 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2586 Refer to parts list for contents of each package. Must be ordered separately: 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. REPAIR PROCEDURE A.Engine Compartment Harness Pn 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1A - ENGINE COMPARTMENT WIRING 3. Remove engine cover. Install the bare eyelet terminal of overlay harness, PN 4362295, to the negative terminal of the ignition coil as shown in Figure 1-A. FIGURE 1B - ENGINE COMPARTMENT WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2587 4. Route and secure the engine overlay harness, PN 4362295, along the existing main engine wiring harness using the existing wiring clips and two tie wraps, PN 6015756 (Figure 1-B). FIGURE 1C - ENGINE COMPARTMENT WIRING 5. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness to the bulkhead connector using the existing wiring clips and three tie wraps, PN 6015756 (Figure 1-C). Loop and tape any excess wire of the engine overlay harness. FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 6. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar multi-purpose grease PN 4318063, and snap into cavity #14 of the engine side of the bulkhead connector (Figure 1-D). B.Instrument Panel Harnesses Pn 4362289, All Models Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2588 FIGURE 2A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) 1. Remove instrument panel left lower trim panel. 2. Insert two bare terminals from instrument panel overlay harness, PN 4362289, into the instrument panel side of the bulkhead connector (Figure 2-A). a. Gray with black tracer wire into cavity #14. b. Dark green wire into cavity #13. INSTRUMENT PANEL WIRING 3. Secure bare eyelet ground terminal (white with black tracer wire) from instrument panel overlay harness, PN 4362289, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). NOTE: CERTAIN VEHICLES ARE ALREADY EQUIPPED WITH THE GROUND SCREW. IF SO, DISCARD THE SUPPLIED SCREW. FIGURE 2C - INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2589 FIGURE 2D - INSTRUMENT PANEL WIRING 4. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-C). Install the extracted terminal (orange wire) into the natural colored 1-way connector supplied with instrument panel overlay harness, PN 4362289. Install the bare terminal (orange wire) from the instrument panel overlay harness, PN 4362289, into the vacated cavity in the ignition switch connector. Reconnect the natural colored 1-way connectors supplied with the instrument panel overlay harness, PN 4362289, and reconnect the ignition switch connectors (Figure 2-C and 2-D). FIGURE 2E - TYPICAL CONTROL MODULE MOUNTING 5. Connect the control (auto shut-down) module, PN 5226640, to the natural colored 8-way connector from instrument panel overlay harness, PN 4362289. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2590 FIGURE 2D - INSTRUMENT PANEL WIRING FIGURE 2F - INSTRUMENT PANEL WIRING 6. Route the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289, to the back of the brake bracket for mating in a later step (Figures 2-B, 2-D, and 2-F). Secure instrument panel overlay harness, PN 4362289, using tie wrap, PN 6015756, to keep it clear of any possible interferences. Only one of the following installation procedures (Step 7) will be used. Take notice of which one applies to the vehicle being repaired. 7. Without Auxiliary Air Conditioning and/or Heater - Jumper Harness PN 4362291 a. Remove instrument panel hood and bezel assembly and remove radio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2591 FIGURE 2D - INSTRUMENT PANEL WIRING b. Route instrument panel jumper harness, PN 4362291, from the back of the brake bracket to the existing 3-way red molded connector. Secure by using existing wiring clips (Figure 2-D). c. Insert the bare bullet terminal (black with white tracer wire) from instrument panel jumper harness, PN 4362291, into the existing 3-way red molded connector from the main instrument panel wiring harness (Figure 2-D). d. Mate the orange colored 1-way connector from instrument panel jumper harness, PN 4362291, to the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). e. Reinstall instrument panel hood and bezel assembly and install radio. FIGURE 2F - INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater and Power Windows - Jumper Harness PN 4362292 a. Disconnect from each other, the two existing brown colored 1-way connectors located near the left instrument panel vent (Figure 2-F). Reconnect these two brown colored 1-way connectors to the two brown colored 1-way connectors from instrument panel jumper harness, PN 4362292 (Figure 2-F). b. Mate the orange colored 1-way connector from the instrument panel jumper harness, PN 4362292, to the orange colored 1-way connector from instrument panel overlay harness, PN 4362289 (Figure 2-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2592 INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater Without Power Windows - Relay Harness PN 4362290 a. Remove instrument panel hood and bezel assembly. Remove radio. b. Install the ignition switch protection relay, PN 4162597, to the back of the brake bracket (mounting location shown in Figure 2-B) and attach instrument panel relay harness, PN 4362290, to relay. c. Secure bare eyelet ground terminal (white wire) from instrument panel relay harness, PN 4362290, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING d. Route the dark blue wire from the instrument panel relay harness, PN 4362290 to the existing 3-way red molded connector using existing wiring clips. Insert bullet terminal (dark blue wire) into red molded connector (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2593 INSTRUMENT PANEL WIRING e. Insert bare bullet terminal (red wire) from instrument panel relay harness, PN 4362290, into the existing 3-way yellow molded connector from the main instrument panel wiring harness (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING f. Mate the orange colored 1-way connector from instrument panel relay harness, PN 4362290, to the colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). g. Install the instrument panel left lower trim panel, instrument panel hood, bezel assembly and radio. C.In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Feed red and yellow molds of body wiring harness, PN 4362293, through slot in the crossmember. Remove existing screw for gauge unit ground. Install eyelet terminal of harness, PN 4362293 (and ground eyelet terminal of 36 gallon tank gauge/pump unit) and torque ground screw to 36 inch pounds. CAUTION: GROUND SCREW MUST BE TIGHTENED SECURELY TO OPERATE ELECTRIC PUMP AND GAUGE UNIT. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2594 FIGURE 3A - BODY WIRING FIGURE 3B - BODY WIRING Install red mold of body harness, PN 4362293, onto red stud of gauge/pump unit. Install yellow mold of harness, PN 4362293, onto black stud of gauge/pump unit (figure 3-a or 3-b). Install molded blade terminal of harness, PN 4362293, onto blade terminal of 22 gallon gauge unit only. NOTE: PREVIOUS GAUGE UNIT GROUND WILL NOT BE USED ON 22 GALLON GAUGE/PUMP UNIT. ON 36 GALLON GAUGE PUMP UNIT, THE GROUND WIRE ON HARNESS PN 4362293 WILL NOT BE USED. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. Set aside the rest of harness, PN 4362293, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. D.Body Wiring Harness Pn 4362293 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2595 FIGURE 3C - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2596 FIGURE 3-F - BODY WIRING 1. Vehicles With 36 Gallon Tank Route harness, PN 4362293, to the right (passenger) side of vehicle along the fuel line tubes and tie wrap (1). At right frame rail, route harness forward to next crossmember (Figures 3-C and 3-E). Tie wrap harness in three (3) places. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2597 FIGURE 3D - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2598 FIGURE 3-F - BODY WIRING Vehicles With 22 Gallon Tank Route harness, PN 4362293, along right frame rail following brake lines (Figures 3-D and 3-E). Tie wrap in two (2) places. NOTE: HARNESS MUST BE ABOVE SHOCK STRUT WITH EITHER 36 OR 22 GALLON TANK. 2. At crossmember, route harness to the left rail following existing brake lines and tie wrap in two (2) places. At left rail, route harness forward through access holes following existing brake lines. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2599 FIGURE 3-F - BODY WIRING NOTE: HARNESS SHOULD BE TIGHT IN THIS AREA THE WRAP IN FOUR (4) PLACES (FIGURE 3-E). 3. At engine compartment, route harness through existing speedometer cable clips to bulkhead connector. If excess wiring exists; loop, tie wrap (2), and install into existing clip (Figure 3-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2600 FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 4. Plug bare terminal of harness, PN 4362293, into cavity #13 of the bulkhead connector (Figure 1-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2601 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2602 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2603 FIGURE 9 - ELECTRIC FUEL PUMP WIRING DIAGRAMW/AUX A/C & HEATER-W/O POWER WINDOWS 5. For all vehicles except those which require a 78 amp alternator package: Reinstall instrument panel side, then engine compartment side of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURES 7, 8, OR 9 FOR OVERALL WIRING DIAGRAMS. E.Engine Compartment Fuel Reservoir/Filter Lnstallation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2604 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER 1. Using template, PN 4418011, mark and drill (from engine side of passenger side chassis rail) two (2) holes .290" diameter (L size drill) as shown in Figure 4-A. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2605 FIGURE 4B - Mounting Fuel Resevoir/Filter 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. NOTE: RUBBER SPLASH SHIELD MAY HAVE TO BE CUT OUT AROUND FUEL RESERVOIR. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube, PN 4306968 (Figure 4-B). 4. Install return hose assembly, PN 4418006, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end (Figure 4-B). 5. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 42O3576. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2606 FIGURE 4B - Mounting Fuel Resevoir/Filter 6. Install one 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the fuel pump outlet tube to the reservoir/filter inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). 7. Install the other 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 8. Tighten all hose clamps to 10 inch pounds. FIGURE 10 9. Type Authorized Modification Label, PN 4275086, as shown in Figure 10 and attach near VECI label. 10. For all models except 1981-1984 equipped with Carter Thermoquad 4BBL carburetor or dual air conditioning units without electrically Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2607 heated rear window defroster. Reconnect battery. Start the engine, and inspect the entire system for fuel leaks and proper wire and hose routing. 11. Reinstall engine cover. F.1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (Pn 4397 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6O22254, (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT, AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6O22254. THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2608 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference with nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose-to-regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. For all models except those equipped with dual air conditioning units, without electrically heated rear window defroster and with 60 amp alternator: 6. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 7. Reinstall engine cover. G.Vehicles Equipped With Dual Air Conditioning Units, Without Electrically Heated Rear Defroster, and With 60 Amp Alternator. I Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2609 HEADLAMP AND DASH WIRING ASSEMBLY 1. Disconnect the battery positive lead (single in-line connection) from the headlamp and dash wiring assembly (Figure 6-A). FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 2. Remove the following wires from the engine compartment side of the bulkhead connector (Figure 6-B). a. Red wire from cavity #39 (ammeter). b. Black wire from cavity #33 (ammeter). Cut off the terminals and wrap tape around each end of both wires to insure that shorting cannot occur. Then tape the wrapped wires back against the main harness. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2610 FIGURE 6-C - 78 AMP ALTERNATOR WIRING 3. Remove the alternator output wire (heavy gauge) from the 60 amp alternator (Figure 6-C). Cut the wire off leaving approximately three (3) inches of wire extending out of the main harness. Tape the end of the lead thoroughly. Then fold and tape the lead back against the main harness to prevent shorting. 4. Remove 60 amp alternator assembly and install 78 amp alternator assembly, PN 4111204, per the service manual alternator replacement procedure. HEADLAMP AND DASH WIRING ASSEMBLY Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2611 FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 5. Beginning at the bulkhead, route and connect the wiring assembly, PN 4362343, as shown in Figure 6-A. Use the existing clip for main harness and tie wrap with three (3) tie wraps, PN 6015756. Insert the two bare terminals from alternator overlay wiring harness, PN 4362343, as shown in Figure 6-B as follows: NOTE: THE 4362343 ALTERNATOR OVERLAY HARNESS WAS MANUFACTURED WITH THE RED AND BLACK WIRES REVERSED. THEREFORE, IT WILL BE NECESSARY TO INSTALL THE BLACK WIRE (LABELED RED) INTO CAVITY #39 (RED WIRE PREVIOUSLY REMOVED), AND THE RED WIRE (LABELED BLACK) INTO CAVITY #33 (BLACK WIRE PREVIOUSLY REMOVED). FAILURE TO REVERSE THESE TWO WIRES WILL RESULT IN THE AMMETER SHOWING THE OPPOSITE CHARGE INDICATION. a. Red wire into cavity #33 (ammeter) - (labeled as black wire). b. Black wire into cavity #39 (ammeter) - (labeled as red wire). 6. Install wiring assembly, PN 4362343, alternator output terminal to new 78 amp alternator. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2612 FIGURE 6A1 7. Connect the battery positive lead and the headlamp and dash wiring assembly lead to those of the alternator overlay wiring assembly, PN 4362343, as shown in circled view of Figure 6-A. 8. Reinstall instrument panel half, then engine compartment half of bulkhead connector and torque to 40 inch pounds. 9. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 10. Reinstall engine cover. POLICY: Reimbursable within the provisions of the warranty and repair manual. TIME ALLOWANCE: Labor Operation No. 14-70-17-94 - All 2.5 Hrs. Optional Equipment: 14-70-17-60 - Carter Thermoquad Carburetor 0.5 Hrs. 14-70-17-61 - With Auxiliary A/C - Without Elec. 0.7 Hrs. Rear Window Defroster 14-70-17-62 - Without Auxiliary A/C 0.3 Hrs. 14-70-17-63 - With Auxiliary A/C - Without 0.4 Hrs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2613 Power Windows FAILURE CODE: AM - Authorized Modification Part List VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 22 GALLON FUEL TANK PACKAGE PART NO. 4397611 QTY PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075432 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Seal - Fuel Tank Gauge 3404451 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 36 GALLON FUEL TANK PACKAGE PART NO. 4397612 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075436 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Gasket - Fuel Tank Sending Unit 4115209 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2614 *It may be necessary to order clamp separately on early released packages. PARTS LIST FUEL PRESSURE REGULATOR PACKAGE FOR 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO.4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 PARTS LIST 78 AMP ALTERNATOR PACKAGE FOR 1981-1985 B MODEL TRUCKS WITH 5.2L OR 5.9L ENGINES PACKAGE PART NO. 4397615 QTY. PART NAME PART NO. 1 78 AMP Alternator Assembly - Complete 4111204 1 Alternator Overlay Wiring Harness 4362343 4 Tie Wrap 6015756 1 Gasket - Bulkhead Connector 4055399 FIGURE 4B - Mounting Fuel Resevoir/Filter 1. Fuel Filter/ Reservoir - 4418012 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2615 2. Screw - Self Tapping - 6022777 (2 Req.) 3. Tube Assy - Fuel Pump to Reservoir - 4306968 4. Return Hose & Sleeve Assy - 4418006 5. Hose Clamps - 6500650 (2 Req.) - 1/4" 6. Hose-Fuel Pump Outlet to Reservoir Inlet - 4203576 7. Hose-Reservoir Outlet to Carburetor or Regulator Fuel Tube - 4203576 8. Hose Clamps - 6500651 (4 Req.) - 5/16" Included but not shown: 2 piece Convolute Tubing - 4279993 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1 SCREW & WASHER - 6022254 2 REGULATOR BRACKET - 4418010 3 REGULATOR - 4418OD9 4 TUBE - REGULATOR TO CARB - 4418008 5 TUBE - RESERVOIR HOSE TO REGULATOR - 4418014 6 SCREW (2 EA.) - REGULATOR TO BRACKET - 6033066 7 CLAMP (5116) - 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pump Pressure ............................................................................................................................ ........................................................ 4.75 psi - 6.25 psi Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 2628 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 2629 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 2630 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 2631 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 2632 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 2633 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 2634 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 2635 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 2636 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 2637 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 2638 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 2639 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 2640 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 2641 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 2642 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock Technical Service Bulletin # 181985A Date: 851201 Fuel System - Vapor Lock Models 1981-1985 Van & Wagon Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 20, 1985 No. 18-19-85 REVISION A P-4782-C This bulletin supersedes Technical Service Bulletin #18-19-85 which should be removed from your files. The model application has been expanded to include 1981 and 1982 model years. SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING TWO PART NUMBERS: Vapor Lock Package With 22 Gallon Fuel Tank PN 4397611 Vapor Lock Package With 36 Gallon Fuel Tank PN 4397612 ADDITIONAL PARTS INFORMATION ON NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 All vehicles equipped with dual air conditioning, without electrically heated rear window defroster, and with 60 amp alternator must order the following package in addition to the vapor lock package. If vehicle is equipped with a 114 amp alternator, do not order this package or make any changes to the charging system. 1 78 AMP Alternator Package PN 4397615 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2647 Refer to parts list for contents of each package. Must be ordered separately: 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. REPAIR PROCEDURE A.Engine Compartment Harness Pn 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1A - ENGINE COMPARTMENT WIRING 3. Remove engine cover. Install the bare eyelet terminal of overlay harness, PN 4362295, to the negative terminal of the ignition coil as shown in Figure 1-A. FIGURE 1B - ENGINE COMPARTMENT WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2648 4. Route and secure the engine overlay harness, PN 4362295, along the existing main engine wiring harness using the existing wiring clips and two tie wraps, PN 6015756 (Figure 1-B). FIGURE 1C - ENGINE COMPARTMENT WIRING 5. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness to the bulkhead connector using the existing wiring clips and three tie wraps, PN 6015756 (Figure 1-C). Loop and tape any excess wire of the engine overlay harness. FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 6. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar multi-purpose grease PN 4318063, and snap into cavity #14 of the engine side of the bulkhead connector (Figure 1-D). B.Instrument Panel Harnesses Pn 4362289, All Models Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2649 FIGURE 2A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) 1. Remove instrument panel left lower trim panel. 2. Insert two bare terminals from instrument panel overlay harness, PN 4362289, into the instrument panel side of the bulkhead connector (Figure 2-A). a. Gray with black tracer wire into cavity #14. b. Dark green wire into cavity #13. INSTRUMENT PANEL WIRING 3. Secure bare eyelet ground terminal (white with black tracer wire) from instrument panel overlay harness, PN 4362289, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). NOTE: CERTAIN VEHICLES ARE ALREADY EQUIPPED WITH THE GROUND SCREW. IF SO, DISCARD THE SUPPLIED SCREW. FIGURE 2C - INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2650 FIGURE 2D - INSTRUMENT PANEL WIRING 4. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-C). Install the extracted terminal (orange wire) into the natural colored 1-way connector supplied with instrument panel overlay harness, PN 4362289. Install the bare terminal (orange wire) from the instrument panel overlay harness, PN 4362289, into the vacated cavity in the ignition switch connector. Reconnect the natural colored 1-way connectors supplied with the instrument panel overlay harness, PN 4362289, and reconnect the ignition switch connectors (Figure 2-C and 2-D). FIGURE 2E - TYPICAL CONTROL MODULE MOUNTING 5. Connect the control (auto shut-down) module, PN 5226640, to the natural colored 8-way connector from instrument panel overlay harness, PN 4362289. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2651 FIGURE 2D - INSTRUMENT PANEL WIRING FIGURE 2F - INSTRUMENT PANEL WIRING 6. Route the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289, to the back of the brake bracket for mating in a later step (Figures 2-B, 2-D, and 2-F). Secure instrument panel overlay harness, PN 4362289, using tie wrap, PN 6015756, to keep it clear of any possible interferences. Only one of the following installation procedures (Step 7) will be used. Take notice of which one applies to the vehicle being repaired. 7. Without Auxiliary Air Conditioning and/or Heater - Jumper Harness PN 4362291 a. Remove instrument panel hood and bezel assembly and remove radio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2652 FIGURE 2D - INSTRUMENT PANEL WIRING b. Route instrument panel jumper harness, PN 4362291, from the back of the brake bracket to the existing 3-way red molded connector. Secure by using existing wiring clips (Figure 2-D). c. Insert the bare bullet terminal (black with white tracer wire) from instrument panel jumper harness, PN 4362291, into the existing 3-way red molded connector from the main instrument panel wiring harness (Figure 2-D). d. Mate the orange colored 1-way connector from instrument panel jumper harness, PN 4362291, to the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). e. Reinstall instrument panel hood and bezel assembly and install radio. FIGURE 2F - INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater and Power Windows - Jumper Harness PN 4362292 a. Disconnect from each other, the two existing brown colored 1-way connectors located near the left instrument panel vent (Figure 2-F). Reconnect these two brown colored 1-way connectors to the two brown colored 1-way connectors from instrument panel jumper harness, PN 4362292 (Figure 2-F). b. Mate the orange colored 1-way connector from the instrument panel jumper harness, PN 4362292, to the orange colored 1-way connector from instrument panel overlay harness, PN 4362289 (Figure 2-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2653 INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater Without Power Windows - Relay Harness PN 4362290 a. Remove instrument panel hood and bezel assembly. Remove radio. b. Install the ignition switch protection relay, PN 4162597, to the back of the brake bracket (mounting location shown in Figure 2-B) and attach instrument panel relay harness, PN 4362290, to relay. c. Secure bare eyelet ground terminal (white wire) from instrument panel relay harness, PN 4362290, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING d. Route the dark blue wire from the instrument panel relay harness, PN 4362290 to the existing 3-way red molded connector using existing wiring clips. Insert bullet terminal (dark blue wire) into red molded connector (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2654 INSTRUMENT PANEL WIRING e. Insert bare bullet terminal (red wire) from instrument panel relay harness, PN 4362290, into the existing 3-way yellow molded connector from the main instrument panel wiring harness (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING f. Mate the orange colored 1-way connector from instrument panel relay harness, PN 4362290, to the colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). g. Install the instrument panel left lower trim panel, instrument panel hood, bezel assembly and radio. C.In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Feed red and yellow molds of body wiring harness, PN 4362293, through slot in the crossmember. Remove existing screw for gauge unit ground. Install eyelet terminal of harness, PN 4362293 (and ground eyelet terminal of 36 gallon tank gauge/pump unit) and torque ground screw to 36 inch pounds. CAUTION: GROUND SCREW MUST BE TIGHTENED SECURELY TO OPERATE ELECTRIC PUMP AND GAUGE UNIT. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2655 FIGURE 3A - BODY WIRING FIGURE 3B - BODY WIRING Install red mold of body harness, PN 4362293, onto red stud of gauge/pump unit. Install yellow mold of harness, PN 4362293, onto black stud of gauge/pump unit (figure 3-a or 3-b). Install molded blade terminal of harness, PN 4362293, onto blade terminal of 22 gallon gauge unit only. NOTE: PREVIOUS GAUGE UNIT GROUND WILL NOT BE USED ON 22 GALLON GAUGE/PUMP UNIT. ON 36 GALLON GAUGE PUMP UNIT, THE GROUND WIRE ON HARNESS PN 4362293 WILL NOT BE USED. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. Set aside the rest of harness, PN 4362293, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. D.Body Wiring Harness Pn 4362293 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2656 FIGURE 3C - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2657 FIGURE 3-F - BODY WIRING 1. Vehicles With 36 Gallon Tank Route harness, PN 4362293, to the right (passenger) side of vehicle along the fuel line tubes and tie wrap (1). At right frame rail, route harness forward to next crossmember (Figures 3-C and 3-E). Tie wrap harness in three (3) places. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2658 FIGURE 3D - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2659 FIGURE 3-F - BODY WIRING Vehicles With 22 Gallon Tank Route harness, PN 4362293, along right frame rail following brake lines (Figures 3-D and 3-E). Tie wrap in two (2) places. NOTE: HARNESS MUST BE ABOVE SHOCK STRUT WITH EITHER 36 OR 22 GALLON TANK. 2. At crossmember, route harness to the left rail following existing brake lines and tie wrap in two (2) places. At left rail, route harness forward through access holes following existing brake lines. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2660 FIGURE 3-F - BODY WIRING NOTE: HARNESS SHOULD BE TIGHT IN THIS AREA THE WRAP IN FOUR (4) PLACES (FIGURE 3-E). 3. At engine compartment, route harness through existing speedometer cable clips to bulkhead connector. If excess wiring exists; loop, tie wrap (2), and install into existing clip (Figure 3-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2661 FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 4. Plug bare terminal of harness, PN 4362293, into cavity #13 of the bulkhead connector (Figure 1-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2662 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2663 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2664 FIGURE 9 - ELECTRIC FUEL PUMP WIRING DIAGRAMW/AUX A/C & HEATER-W/O POWER WINDOWS 5. For all vehicles except those which require a 78 amp alternator package: Reinstall instrument panel side, then engine compartment side of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURES 7, 8, OR 9 FOR OVERALL WIRING DIAGRAMS. E.Engine Compartment Fuel Reservoir/Filter Lnstallation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2665 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER 1. Using template, PN 4418011, mark and drill (from engine side of passenger side chassis rail) two (2) holes .290" diameter (L size drill) as shown in Figure 4-A. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2666 FIGURE 4B - Mounting Fuel Resevoir/Filter 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. NOTE: RUBBER SPLASH SHIELD MAY HAVE TO BE CUT OUT AROUND FUEL RESERVOIR. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube, PN 4306968 (Figure 4-B). 4. Install return hose assembly, PN 4418006, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end (Figure 4-B). 5. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 42O3576. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2667 FIGURE 4B - Mounting Fuel Resevoir/Filter 6. Install one 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the fuel pump outlet tube to the reservoir/filter inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). 7. Install the other 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 8. Tighten all hose clamps to 10 inch pounds. FIGURE 10 9. Type Authorized Modification Label, PN 4275086, as shown in Figure 10 and attach near VECI label. 10. For all models except 1981-1984 equipped with Carter Thermoquad 4BBL carburetor or dual air conditioning units without electrically Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2668 heated rear window defroster. Reconnect battery. Start the engine, and inspect the entire system for fuel leaks and proper wire and hose routing. 11. Reinstall engine cover. F.1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (Pn 4397 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6O22254, (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT, AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6O22254. THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2669 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference with nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose-to-regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. For all models except those equipped with dual air conditioning units, without electrically heated rear window defroster and with 60 amp alternator: 6. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 7. Reinstall engine cover. G.Vehicles Equipped With Dual Air Conditioning Units, Without Electrically Heated Rear Defroster, and With 60 Amp Alternator. I Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2670 HEADLAMP AND DASH WIRING ASSEMBLY 1. Disconnect the battery positive lead (single in-line connection) from the headlamp and dash wiring assembly (Figure 6-A). FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 2. Remove the following wires from the engine compartment side of the bulkhead connector (Figure 6-B). a. Red wire from cavity #39 (ammeter). b. Black wire from cavity #33 (ammeter). Cut off the terminals and wrap tape around each end of both wires to insure that shorting cannot occur. Then tape the wrapped wires back against the main harness. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2671 FIGURE 6-C - 78 AMP ALTERNATOR WIRING 3. Remove the alternator output wire (heavy gauge) from the 60 amp alternator (Figure 6-C). Cut the wire off leaving approximately three (3) inches of wire extending out of the main harness. Tape the end of the lead thoroughly. Then fold and tape the lead back against the main harness to prevent shorting. 4. Remove 60 amp alternator assembly and install 78 amp alternator assembly, PN 4111204, per the service manual alternator replacement procedure. HEADLAMP AND DASH WIRING ASSEMBLY Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2672 FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 5. Beginning at the bulkhead, route and connect the wiring assembly, PN 4362343, as shown in Figure 6-A. Use the existing clip for main harness and tie wrap with three (3) tie wraps, PN 6015756. Insert the two bare terminals from alternator overlay wiring harness, PN 4362343, as shown in Figure 6-B as follows: NOTE: THE 4362343 ALTERNATOR OVERLAY HARNESS WAS MANUFACTURED WITH THE RED AND BLACK WIRES REVERSED. THEREFORE, IT WILL BE NECESSARY TO INSTALL THE BLACK WIRE (LABELED RED) INTO CAVITY #39 (RED WIRE PREVIOUSLY REMOVED), AND THE RED WIRE (LABELED BLACK) INTO CAVITY #33 (BLACK WIRE PREVIOUSLY REMOVED). FAILURE TO REVERSE THESE TWO WIRES WILL RESULT IN THE AMMETER SHOWING THE OPPOSITE CHARGE INDICATION. a. Red wire into cavity #33 (ammeter) - (labeled as black wire). b. Black wire into cavity #39 (ammeter) - (labeled as red wire). 6. Install wiring assembly, PN 4362343, alternator output terminal to new 78 amp alternator. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2673 FIGURE 6A1 7. Connect the battery positive lead and the headlamp and dash wiring assembly lead to those of the alternator overlay wiring assembly, PN 4362343, as shown in circled view of Figure 6-A. 8. Reinstall instrument panel half, then engine compartment half of bulkhead connector and torque to 40 inch pounds. 9. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 10. Reinstall engine cover. POLICY: Reimbursable within the provisions of the warranty and repair manual. TIME ALLOWANCE: Labor Operation No. 14-70-17-94 - All 2.5 Hrs. Optional Equipment: 14-70-17-60 - Carter Thermoquad Carburetor 0.5 Hrs. 14-70-17-61 - With Auxiliary A/C - Without Elec. 0.7 Hrs. Rear Window Defroster 14-70-17-62 - Without Auxiliary A/C 0.3 Hrs. 14-70-17-63 - With Auxiliary A/C - Without 0.4 Hrs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2674 Power Windows FAILURE CODE: AM - Authorized Modification Part List VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 22 GALLON FUEL TANK PACKAGE PART NO. 4397611 QTY PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075432 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Seal - Fuel Tank Gauge 3404451 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 36 GALLON FUEL TANK PACKAGE PART NO. 4397612 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075436 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Gasket - Fuel Tank Sending Unit 4115209 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2675 *It may be necessary to order clamp separately on early released packages. PARTS LIST FUEL PRESSURE REGULATOR PACKAGE FOR 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO.4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 PARTS LIST 78 AMP ALTERNATOR PACKAGE FOR 1981-1985 B MODEL TRUCKS WITH 5.2L OR 5.9L ENGINES PACKAGE PART NO. 4397615 QTY. PART NAME PART NO. 1 78 AMP Alternator Assembly - Complete 4111204 1 Alternator Overlay Wiring Harness 4362343 4 Tie Wrap 6015756 1 Gasket - Bulkhead Connector 4055399 FIGURE 4B - Mounting Fuel Resevoir/Filter 1. Fuel Filter/ Reservoir - 4418012 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > Customer Interest for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System Vapor Lock > Page 2676 2. Screw - Self Tapping - 6022777 (2 Req.) 3. Tube Assy - Fuel Pump to Reservoir - 4306968 4. Return Hose & Sleeve Assy - 4418006 5. Hose Clamps - 6500650 (2 Req.) - 1/4" 6. Hose-Fuel Pump Outlet to Reservoir Inlet - 4203576 7. Hose-Reservoir Outlet to Carburetor or Regulator Fuel Tube - 4203576 8. Hose Clamps - 6500651 (4 Req.) - 5/16" Included but not shown: 2 piece Convolute Tubing - 4279993 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1 SCREW & WASHER - 6022254 2 REGULATOR BRACKET - 4418010 3 REGULATOR - 4418OD9 4 TUBE - REGULATOR TO CARB - 4418008 5 TUBE - RESERVOIR HOSE TO REGULATOR - 4418014 6 SCREW (2 EA.) - REGULATOR TO BRACKET - 6033066 7 CLAMP (5116) - 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2682 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2683 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2684 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2685 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2686 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2687 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2688 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2689 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2690 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2691 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2692 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2693 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2694 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2695 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2696 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock Technical Service Bulletin # 181985A Date: 851201 Fuel System - Vapor Lock Models 1981-1985 Van & Wagon Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 20, 1985 No. 18-19-85 REVISION A P-4782-C This bulletin supersedes Technical Service Bulletin #18-19-85 which should be removed from your files. The model application has been expanded to include 1981 and 1982 model years. SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING TWO PART NUMBERS: Vapor Lock Package With 22 Gallon Fuel Tank PN 4397611 Vapor Lock Package With 36 Gallon Fuel Tank PN 4397612 ADDITIONAL PARTS INFORMATION ON NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 All vehicles equipped with dual air conditioning, without electrically heated rear window defroster, and with 60 amp alternator must order the following package in addition to the vapor lock package. If vehicle is equipped with a 114 amp alternator, do not order this package or make any changes to the charging system. 1 78 AMP Alternator Package PN 4397615 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2701 Refer to parts list for contents of each package. Must be ordered separately: 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. REPAIR PROCEDURE A.Engine Compartment Harness Pn 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1A - ENGINE COMPARTMENT WIRING 3. Remove engine cover. Install the bare eyelet terminal of overlay harness, PN 4362295, to the negative terminal of the ignition coil as shown in Figure 1-A. FIGURE 1B - ENGINE COMPARTMENT WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2702 4. Route and secure the engine overlay harness, PN 4362295, along the existing main engine wiring harness using the existing wiring clips and two tie wraps, PN 6015756 (Figure 1-B). FIGURE 1C - ENGINE COMPARTMENT WIRING 5. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness to the bulkhead connector using the existing wiring clips and three tie wraps, PN 6015756 (Figure 1-C). Loop and tape any excess wire of the engine overlay harness. FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 6. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar multi-purpose grease PN 4318063, and snap into cavity #14 of the engine side of the bulkhead connector (Figure 1-D). B.Instrument Panel Harnesses Pn 4362289, All Models Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2703 FIGURE 2A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) 1. Remove instrument panel left lower trim panel. 2. Insert two bare terminals from instrument panel overlay harness, PN 4362289, into the instrument panel side of the bulkhead connector (Figure 2-A). a. Gray with black tracer wire into cavity #14. b. Dark green wire into cavity #13. INSTRUMENT PANEL WIRING 3. Secure bare eyelet ground terminal (white with black tracer wire) from instrument panel overlay harness, PN 4362289, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). NOTE: CERTAIN VEHICLES ARE ALREADY EQUIPPED WITH THE GROUND SCREW. IF SO, DISCARD THE SUPPLIED SCREW. FIGURE 2C - INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2704 FIGURE 2D - INSTRUMENT PANEL WIRING 4. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-C). Install the extracted terminal (orange wire) into the natural colored 1-way connector supplied with instrument panel overlay harness, PN 4362289. Install the bare terminal (orange wire) from the instrument panel overlay harness, PN 4362289, into the vacated cavity in the ignition switch connector. Reconnect the natural colored 1-way connectors supplied with the instrument panel overlay harness, PN 4362289, and reconnect the ignition switch connectors (Figure 2-C and 2-D). FIGURE 2E - TYPICAL CONTROL MODULE MOUNTING 5. Connect the control (auto shut-down) module, PN 5226640, to the natural colored 8-way connector from instrument panel overlay harness, PN 4362289. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2705 FIGURE 2D - INSTRUMENT PANEL WIRING FIGURE 2F - INSTRUMENT PANEL WIRING 6. Route the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289, to the back of the brake bracket for mating in a later step (Figures 2-B, 2-D, and 2-F). Secure instrument panel overlay harness, PN 4362289, using tie wrap, PN 6015756, to keep it clear of any possible interferences. Only one of the following installation procedures (Step 7) will be used. Take notice of which one applies to the vehicle being repaired. 7. Without Auxiliary Air Conditioning and/or Heater - Jumper Harness PN 4362291 a. Remove instrument panel hood and bezel assembly and remove radio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2706 FIGURE 2D - INSTRUMENT PANEL WIRING b. Route instrument panel jumper harness, PN 4362291, from the back of the brake bracket to the existing 3-way red molded connector. Secure by using existing wiring clips (Figure 2-D). c. Insert the bare bullet terminal (black with white tracer wire) from instrument panel jumper harness, PN 4362291, into the existing 3-way red molded connector from the main instrument panel wiring harness (Figure 2-D). d. Mate the orange colored 1-way connector from instrument panel jumper harness, PN 4362291, to the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). e. Reinstall instrument panel hood and bezel assembly and install radio. FIGURE 2F - INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater and Power Windows - Jumper Harness PN 4362292 a. Disconnect from each other, the two existing brown colored 1-way connectors located near the left instrument panel vent (Figure 2-F). Reconnect these two brown colored 1-way connectors to the two brown colored 1-way connectors from instrument panel jumper harness, PN 4362292 (Figure 2-F). b. Mate the orange colored 1-way connector from the instrument panel jumper harness, PN 4362292, to the orange colored 1-way connector from instrument panel overlay harness, PN 4362289 (Figure 2-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2707 INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater Without Power Windows - Relay Harness PN 4362290 a. Remove instrument panel hood and bezel assembly. Remove radio. b. Install the ignition switch protection relay, PN 4162597, to the back of the brake bracket (mounting location shown in Figure 2-B) and attach instrument panel relay harness, PN 4362290, to relay. c. Secure bare eyelet ground terminal (white wire) from instrument panel relay harness, PN 4362290, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING d. Route the dark blue wire from the instrument panel relay harness, PN 4362290 to the existing 3-way red molded connector using existing wiring clips. Insert bullet terminal (dark blue wire) into red molded connector (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2708 INSTRUMENT PANEL WIRING e. Insert bare bullet terminal (red wire) from instrument panel relay harness, PN 4362290, into the existing 3-way yellow molded connector from the main instrument panel wiring harness (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING f. Mate the orange colored 1-way connector from instrument panel relay harness, PN 4362290, to the colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). g. Install the instrument panel left lower trim panel, instrument panel hood, bezel assembly and radio. C.In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Feed red and yellow molds of body wiring harness, PN 4362293, through slot in the crossmember. Remove existing screw for gauge unit ground. Install eyelet terminal of harness, PN 4362293 (and ground eyelet terminal of 36 gallon tank gauge/pump unit) and torque ground screw to 36 inch pounds. CAUTION: GROUND SCREW MUST BE TIGHTENED SECURELY TO OPERATE ELECTRIC PUMP AND GAUGE UNIT. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2709 FIGURE 3A - BODY WIRING FIGURE 3B - BODY WIRING Install red mold of body harness, PN 4362293, onto red stud of gauge/pump unit. Install yellow mold of harness, PN 4362293, onto black stud of gauge/pump unit (figure 3-a or 3-b). Install molded blade terminal of harness, PN 4362293, onto blade terminal of 22 gallon gauge unit only. NOTE: PREVIOUS GAUGE UNIT GROUND WILL NOT BE USED ON 22 GALLON GAUGE/PUMP UNIT. ON 36 GALLON GAUGE PUMP UNIT, THE GROUND WIRE ON HARNESS PN 4362293 WILL NOT BE USED. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. Set aside the rest of harness, PN 4362293, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. D.Body Wiring Harness Pn 4362293 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2710 FIGURE 3C - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2711 FIGURE 3-F - BODY WIRING 1. Vehicles With 36 Gallon Tank Route harness, PN 4362293, to the right (passenger) side of vehicle along the fuel line tubes and tie wrap (1). At right frame rail, route harness forward to next crossmember (Figures 3-C and 3-E). Tie wrap harness in three (3) places. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2712 FIGURE 3D - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2713 FIGURE 3-F - BODY WIRING Vehicles With 22 Gallon Tank Route harness, PN 4362293, along right frame rail following brake lines (Figures 3-D and 3-E). Tie wrap in two (2) places. NOTE: HARNESS MUST BE ABOVE SHOCK STRUT WITH EITHER 36 OR 22 GALLON TANK. 2. At crossmember, route harness to the left rail following existing brake lines and tie wrap in two (2) places. At left rail, route harness forward through access holes following existing brake lines. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2714 FIGURE 3-F - BODY WIRING NOTE: HARNESS SHOULD BE TIGHT IN THIS AREA THE WRAP IN FOUR (4) PLACES (FIGURE 3-E). 3. At engine compartment, route harness through existing speedometer cable clips to bulkhead connector. If excess wiring exists; loop, tie wrap (2), and install into existing clip (Figure 3-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2715 FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 4. Plug bare terminal of harness, PN 4362293, into cavity #13 of the bulkhead connector (Figure 1-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2716 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2717 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2718 FIGURE 9 - ELECTRIC FUEL PUMP WIRING DIAGRAMW/AUX A/C & HEATER-W/O POWER WINDOWS 5. For all vehicles except those which require a 78 amp alternator package: Reinstall instrument panel side, then engine compartment side of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURES 7, 8, OR 9 FOR OVERALL WIRING DIAGRAMS. E.Engine Compartment Fuel Reservoir/Filter Lnstallation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2719 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER 1. Using template, PN 4418011, mark and drill (from engine side of passenger side chassis rail) two (2) holes .290" diameter (L size drill) as shown in Figure 4-A. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2720 FIGURE 4B - Mounting Fuel Resevoir/Filter 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. NOTE: RUBBER SPLASH SHIELD MAY HAVE TO BE CUT OUT AROUND FUEL RESERVOIR. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube, PN 4306968 (Figure 4-B). 4. Install return hose assembly, PN 4418006, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end (Figure 4-B). 5. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 42O3576. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2721 FIGURE 4B - Mounting Fuel Resevoir/Filter 6. Install one 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the fuel pump outlet tube to the reservoir/filter inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). 7. Install the other 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 8. Tighten all hose clamps to 10 inch pounds. FIGURE 10 9. Type Authorized Modification Label, PN 4275086, as shown in Figure 10 and attach near VECI label. 10. For all models except 1981-1984 equipped with Carter Thermoquad 4BBL carburetor or dual air conditioning units without electrically Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2722 heated rear window defroster. Reconnect battery. Start the engine, and inspect the entire system for fuel leaks and proper wire and hose routing. 11. Reinstall engine cover. F.1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (Pn 4397 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6O22254, (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT, AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6O22254. THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2723 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference with nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose-to-regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. For all models except those equipped with dual air conditioning units, without electrically heated rear window defroster and with 60 amp alternator: 6. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 7. Reinstall engine cover. G.Vehicles Equipped With Dual Air Conditioning Units, Without Electrically Heated Rear Defroster, and With 60 Amp Alternator. I Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2724 HEADLAMP AND DASH WIRING ASSEMBLY 1. Disconnect the battery positive lead (single in-line connection) from the headlamp and dash wiring assembly (Figure 6-A). FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 2. Remove the following wires from the engine compartment side of the bulkhead connector (Figure 6-B). a. Red wire from cavity #39 (ammeter). b. Black wire from cavity #33 (ammeter). Cut off the terminals and wrap tape around each end of both wires to insure that shorting cannot occur. Then tape the wrapped wires back against the main harness. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2725 FIGURE 6-C - 78 AMP ALTERNATOR WIRING 3. Remove the alternator output wire (heavy gauge) from the 60 amp alternator (Figure 6-C). Cut the wire off leaving approximately three (3) inches of wire extending out of the main harness. Tape the end of the lead thoroughly. Then fold and tape the lead back against the main harness to prevent shorting. 4. Remove 60 amp alternator assembly and install 78 amp alternator assembly, PN 4111204, per the service manual alternator replacement procedure. HEADLAMP AND DASH WIRING ASSEMBLY Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2726 FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 5. Beginning at the bulkhead, route and connect the wiring assembly, PN 4362343, as shown in Figure 6-A. Use the existing clip for main harness and tie wrap with three (3) tie wraps, PN 6015756. Insert the two bare terminals from alternator overlay wiring harness, PN 4362343, as shown in Figure 6-B as follows: NOTE: THE 4362343 ALTERNATOR OVERLAY HARNESS WAS MANUFACTURED WITH THE RED AND BLACK WIRES REVERSED. THEREFORE, IT WILL BE NECESSARY TO INSTALL THE BLACK WIRE (LABELED RED) INTO CAVITY #39 (RED WIRE PREVIOUSLY REMOVED), AND THE RED WIRE (LABELED BLACK) INTO CAVITY #33 (BLACK WIRE PREVIOUSLY REMOVED). FAILURE TO REVERSE THESE TWO WIRES WILL RESULT IN THE AMMETER SHOWING THE OPPOSITE CHARGE INDICATION. a. Red wire into cavity #33 (ammeter) - (labeled as black wire). b. Black wire into cavity #39 (ammeter) - (labeled as red wire). 6. Install wiring assembly, PN 4362343, alternator output terminal to new 78 amp alternator. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2727 FIGURE 6A1 7. Connect the battery positive lead and the headlamp and dash wiring assembly lead to those of the alternator overlay wiring assembly, PN 4362343, as shown in circled view of Figure 6-A. 8. Reinstall instrument panel half, then engine compartment half of bulkhead connector and torque to 40 inch pounds. 9. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 10. Reinstall engine cover. POLICY: Reimbursable within the provisions of the warranty and repair manual. TIME ALLOWANCE: Labor Operation No. 14-70-17-94 - All 2.5 Hrs. Optional Equipment: 14-70-17-60 - Carter Thermoquad Carburetor 0.5 Hrs. 14-70-17-61 - With Auxiliary A/C - Without Elec. 0.7 Hrs. Rear Window Defroster 14-70-17-62 - Without Auxiliary A/C 0.3 Hrs. 14-70-17-63 - With Auxiliary A/C - Without 0.4 Hrs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2728 Power Windows FAILURE CODE: AM - Authorized Modification Part List VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 22 GALLON FUEL TANK PACKAGE PART NO. 4397611 QTY PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075432 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Seal - Fuel Tank Gauge 3404451 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 36 GALLON FUEL TANK PACKAGE PART NO. 4397612 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075436 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Gasket - Fuel Tank Sending Unit 4115209 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2729 *It may be necessary to order clamp separately on early released packages. PARTS LIST FUEL PRESSURE REGULATOR PACKAGE FOR 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO.4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 PARTS LIST 78 AMP ALTERNATOR PACKAGE FOR 1981-1985 B MODEL TRUCKS WITH 5.2L OR 5.9L ENGINES PACKAGE PART NO. 4397615 QTY. PART NAME PART NO. 1 78 AMP Alternator Assembly - Complete 4111204 1 Alternator Overlay Wiring Harness 4362343 4 Tie Wrap 6015756 1 Gasket - Bulkhead Connector 4055399 FIGURE 4B - Mounting Fuel Resevoir/Filter 1. Fuel Filter/ Reservoir - 4418012 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Reservoir > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Reservoir: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2730 2. Screw - Self Tapping - 6022777 (2 Req.) 3. Tube Assy - Fuel Pump to Reservoir - 4306968 4. Return Hose & Sleeve Assy - 4418006 5. Hose Clamps - 6500650 (2 Req.) - 1/4" 6. Hose-Fuel Pump Outlet to Reservoir Inlet - 4203576 7. Hose-Reservoir Outlet to Carburetor or Regulator Fuel Tube - 4203576 8. Hose Clamps - 6500651 (4 Req.) - 5/16" Included but not shown: 2 piece Convolute Tubing - 4279993 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1 SCREW & WASHER - 6022254 2 REGULATOR BRACKET - 4418010 3 REGULATOR - 4418OD9 4 TUBE - REGULATOR TO CARB - 4418008 5 TUBE - RESERVOIR HOSE TO REGULATOR - 4418014 6 SCREW (2 EA.) - REGULATOR TO BRACKET - 6033066 7 CLAMP (5116) - 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2740 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2741 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2742 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2743 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2744 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2745 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2746 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2747 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2748 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2749 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2750 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2751 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2752 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2753 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2754 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock Technical Service Bulletin # 181985A Date: 851201 Fuel System - Vapor Lock Models 1981-1985 Van & Wagon Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 20, 1985 No. 18-19-85 REVISION A P-4782-C This bulletin supersedes Technical Service Bulletin #18-19-85 which should be removed from your files. The model application has been expanded to include 1981 and 1982 model years. SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING TWO PART NUMBERS: Vapor Lock Package With 22 Gallon Fuel Tank PN 4397611 Vapor Lock Package With 36 Gallon Fuel Tank PN 4397612 ADDITIONAL PARTS INFORMATION ON NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 All vehicles equipped with dual air conditioning, without electrically heated rear window defroster, and with 60 amp alternator must order the following package in addition to the vapor lock package. If vehicle is equipped with a 114 amp alternator, do not order this package or make any changes to the charging system. 1 78 AMP Alternator Package PN 4397615 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2759 Refer to parts list for contents of each package. Must be ordered separately: 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. REPAIR PROCEDURE A.Engine Compartment Harness Pn 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1A - ENGINE COMPARTMENT WIRING 3. Remove engine cover. Install the bare eyelet terminal of overlay harness, PN 4362295, to the negative terminal of the ignition coil as shown in Figure 1-A. FIGURE 1B - ENGINE COMPARTMENT WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2760 4. Route and secure the engine overlay harness, PN 4362295, along the existing main engine wiring harness using the existing wiring clips and two tie wraps, PN 6015756 (Figure 1-B). FIGURE 1C - ENGINE COMPARTMENT WIRING 5. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness to the bulkhead connector using the existing wiring clips and three tie wraps, PN 6015756 (Figure 1-C). Loop and tape any excess wire of the engine overlay harness. FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 6. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar multi-purpose grease PN 4318063, and snap into cavity #14 of the engine side of the bulkhead connector (Figure 1-D). B.Instrument Panel Harnesses Pn 4362289, All Models Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2761 FIGURE 2A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) 1. Remove instrument panel left lower trim panel. 2. Insert two bare terminals from instrument panel overlay harness, PN 4362289, into the instrument panel side of the bulkhead connector (Figure 2-A). a. Gray with black tracer wire into cavity #14. b. Dark green wire into cavity #13. INSTRUMENT PANEL WIRING 3. Secure bare eyelet ground terminal (white with black tracer wire) from instrument panel overlay harness, PN 4362289, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). NOTE: CERTAIN VEHICLES ARE ALREADY EQUIPPED WITH THE GROUND SCREW. IF SO, DISCARD THE SUPPLIED SCREW. FIGURE 2C - INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2762 FIGURE 2D - INSTRUMENT PANEL WIRING 4. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-C). Install the extracted terminal (orange wire) into the natural colored 1-way connector supplied with instrument panel overlay harness, PN 4362289. Install the bare terminal (orange wire) from the instrument panel overlay harness, PN 4362289, into the vacated cavity in the ignition switch connector. Reconnect the natural colored 1-way connectors supplied with the instrument panel overlay harness, PN 4362289, and reconnect the ignition switch connectors (Figure 2-C and 2-D). FIGURE 2E - TYPICAL CONTROL MODULE MOUNTING 5. Connect the control (auto shut-down) module, PN 5226640, to the natural colored 8-way connector from instrument panel overlay harness, PN 4362289. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2763 FIGURE 2D - INSTRUMENT PANEL WIRING FIGURE 2F - INSTRUMENT PANEL WIRING 6. Route the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289, to the back of the brake bracket for mating in a later step (Figures 2-B, 2-D, and 2-F). Secure instrument panel overlay harness, PN 4362289, using tie wrap, PN 6015756, to keep it clear of any possible interferences. Only one of the following installation procedures (Step 7) will be used. Take notice of which one applies to the vehicle being repaired. 7. Without Auxiliary Air Conditioning and/or Heater - Jumper Harness PN 4362291 a. Remove instrument panel hood and bezel assembly and remove radio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2764 FIGURE 2D - INSTRUMENT PANEL WIRING b. Route instrument panel jumper harness, PN 4362291, from the back of the brake bracket to the existing 3-way red molded connector. Secure by using existing wiring clips (Figure 2-D). c. Insert the bare bullet terminal (black with white tracer wire) from instrument panel jumper harness, PN 4362291, into the existing 3-way red molded connector from the main instrument panel wiring harness (Figure 2-D). d. Mate the orange colored 1-way connector from instrument panel jumper harness, PN 4362291, to the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). e. Reinstall instrument panel hood and bezel assembly and install radio. FIGURE 2F - INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater and Power Windows - Jumper Harness PN 4362292 a. Disconnect from each other, the two existing brown colored 1-way connectors located near the left instrument panel vent (Figure 2-F). Reconnect these two brown colored 1-way connectors to the two brown colored 1-way connectors from instrument panel jumper harness, PN 4362292 (Figure 2-F). b. Mate the orange colored 1-way connector from the instrument panel jumper harness, PN 4362292, to the orange colored 1-way connector from instrument panel overlay harness, PN 4362289 (Figure 2-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2765 INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater Without Power Windows - Relay Harness PN 4362290 a. Remove instrument panel hood and bezel assembly. Remove radio. b. Install the ignition switch protection relay, PN 4162597, to the back of the brake bracket (mounting location shown in Figure 2-B) and attach instrument panel relay harness, PN 4362290, to relay. c. Secure bare eyelet ground terminal (white wire) from instrument panel relay harness, PN 4362290, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING d. Route the dark blue wire from the instrument panel relay harness, PN 4362290 to the existing 3-way red molded connector using existing wiring clips. Insert bullet terminal (dark blue wire) into red molded connector (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2766 INSTRUMENT PANEL WIRING e. Insert bare bullet terminal (red wire) from instrument panel relay harness, PN 4362290, into the existing 3-way yellow molded connector from the main instrument panel wiring harness (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING f. Mate the orange colored 1-way connector from instrument panel relay harness, PN 4362290, to the colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). g. Install the instrument panel left lower trim panel, instrument panel hood, bezel assembly and radio. C.In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Feed red and yellow molds of body wiring harness, PN 4362293, through slot in the crossmember. Remove existing screw for gauge unit ground. Install eyelet terminal of harness, PN 4362293 (and ground eyelet terminal of 36 gallon tank gauge/pump unit) and torque ground screw to 36 inch pounds. CAUTION: GROUND SCREW MUST BE TIGHTENED SECURELY TO OPERATE ELECTRIC PUMP AND GAUGE UNIT. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2767 FIGURE 3A - BODY WIRING FIGURE 3B - BODY WIRING Install red mold of body harness, PN 4362293, onto red stud of gauge/pump unit. Install yellow mold of harness, PN 4362293, onto black stud of gauge/pump unit (figure 3-a or 3-b). Install molded blade terminal of harness, PN 4362293, onto blade terminal of 22 gallon gauge unit only. NOTE: PREVIOUS GAUGE UNIT GROUND WILL NOT BE USED ON 22 GALLON GAUGE/PUMP UNIT. ON 36 GALLON GAUGE PUMP UNIT, THE GROUND WIRE ON HARNESS PN 4362293 WILL NOT BE USED. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. Set aside the rest of harness, PN 4362293, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. D.Body Wiring Harness Pn 4362293 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2768 FIGURE 3C - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2769 FIGURE 3-F - BODY WIRING 1. Vehicles With 36 Gallon Tank Route harness, PN 4362293, to the right (passenger) side of vehicle along the fuel line tubes and tie wrap (1). At right frame rail, route harness forward to next crossmember (Figures 3-C and 3-E). Tie wrap harness in three (3) places. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2770 FIGURE 3D - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2771 FIGURE 3-F - BODY WIRING Vehicles With 22 Gallon Tank Route harness, PN 4362293, along right frame rail following brake lines (Figures 3-D and 3-E). Tie wrap in two (2) places. NOTE: HARNESS MUST BE ABOVE SHOCK STRUT WITH EITHER 36 OR 22 GALLON TANK. 2. At crossmember, route harness to the left rail following existing brake lines and tie wrap in two (2) places. At left rail, route harness forward through access holes following existing brake lines. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2772 FIGURE 3-F - BODY WIRING NOTE: HARNESS SHOULD BE TIGHT IN THIS AREA THE WRAP IN FOUR (4) PLACES (FIGURE 3-E). 3. At engine compartment, route harness through existing speedometer cable clips to bulkhead connector. If excess wiring exists; loop, tie wrap (2), and install into existing clip (Figure 3-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2773 FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 4. Plug bare terminal of harness, PN 4362293, into cavity #13 of the bulkhead connector (Figure 1-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2774 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2775 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2776 FIGURE 9 - ELECTRIC FUEL PUMP WIRING DIAGRAMW/AUX A/C & HEATER-W/O POWER WINDOWS 5. For all vehicles except those which require a 78 amp alternator package: Reinstall instrument panel side, then engine compartment side of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURES 7, 8, OR 9 FOR OVERALL WIRING DIAGRAMS. E.Engine Compartment Fuel Reservoir/Filter Lnstallation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2777 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER 1. Using template, PN 4418011, mark and drill (from engine side of passenger side chassis rail) two (2) holes .290" diameter (L size drill) as shown in Figure 4-A. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2778 FIGURE 4B - Mounting Fuel Resevoir/Filter 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. NOTE: RUBBER SPLASH SHIELD MAY HAVE TO BE CUT OUT AROUND FUEL RESERVOIR. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube, PN 4306968 (Figure 4-B). 4. Install return hose assembly, PN 4418006, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end (Figure 4-B). 5. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 42O3576. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2779 FIGURE 4B - Mounting Fuel Resevoir/Filter 6. Install one 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the fuel pump outlet tube to the reservoir/filter inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). 7. Install the other 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 8. Tighten all hose clamps to 10 inch pounds. FIGURE 10 9. Type Authorized Modification Label, PN 4275086, as shown in Figure 10 and attach near VECI label. 10. For all models except 1981-1984 equipped with Carter Thermoquad 4BBL carburetor or dual air conditioning units without electrically Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2780 heated rear window defroster. Reconnect battery. Start the engine, and inspect the entire system for fuel leaks and proper wire and hose routing. 11. Reinstall engine cover. F.1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (Pn 4397 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6O22254, (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT, AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6O22254. THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2781 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference with nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose-to-regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. For all models except those equipped with dual air conditioning units, without electrically heated rear window defroster and with 60 amp alternator: 6. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 7. Reinstall engine cover. G.Vehicles Equipped With Dual Air Conditioning Units, Without Electrically Heated Rear Defroster, and With 60 Amp Alternator. I Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2782 HEADLAMP AND DASH WIRING ASSEMBLY 1. Disconnect the battery positive lead (single in-line connection) from the headlamp and dash wiring assembly (Figure 6-A). FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 2. Remove the following wires from the engine compartment side of the bulkhead connector (Figure 6-B). a. Red wire from cavity #39 (ammeter). b. Black wire from cavity #33 (ammeter). Cut off the terminals and wrap tape around each end of both wires to insure that shorting cannot occur. Then tape the wrapped wires back against the main harness. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2783 FIGURE 6-C - 78 AMP ALTERNATOR WIRING 3. Remove the alternator output wire (heavy gauge) from the 60 amp alternator (Figure 6-C). Cut the wire off leaving approximately three (3) inches of wire extending out of the main harness. Tape the end of the lead thoroughly. Then fold and tape the lead back against the main harness to prevent shorting. 4. Remove 60 amp alternator assembly and install 78 amp alternator assembly, PN 4111204, per the service manual alternator replacement procedure. HEADLAMP AND DASH WIRING ASSEMBLY Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2784 FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 5. Beginning at the bulkhead, route and connect the wiring assembly, PN 4362343, as shown in Figure 6-A. Use the existing clip for main harness and tie wrap with three (3) tie wraps, PN 6015756. Insert the two bare terminals from alternator overlay wiring harness, PN 4362343, as shown in Figure 6-B as follows: NOTE: THE 4362343 ALTERNATOR OVERLAY HARNESS WAS MANUFACTURED WITH THE RED AND BLACK WIRES REVERSED. THEREFORE, IT WILL BE NECESSARY TO INSTALL THE BLACK WIRE (LABELED RED) INTO CAVITY #39 (RED WIRE PREVIOUSLY REMOVED), AND THE RED WIRE (LABELED BLACK) INTO CAVITY #33 (BLACK WIRE PREVIOUSLY REMOVED). FAILURE TO REVERSE THESE TWO WIRES WILL RESULT IN THE AMMETER SHOWING THE OPPOSITE CHARGE INDICATION. a. Red wire into cavity #33 (ammeter) - (labeled as black wire). b. Black wire into cavity #39 (ammeter) - (labeled as red wire). 6. Install wiring assembly, PN 4362343, alternator output terminal to new 78 amp alternator. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2785 FIGURE 6A1 7. Connect the battery positive lead and the headlamp and dash wiring assembly lead to those of the alternator overlay wiring assembly, PN 4362343, as shown in circled view of Figure 6-A. 8. Reinstall instrument panel half, then engine compartment half of bulkhead connector and torque to 40 inch pounds. 9. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 10. Reinstall engine cover. POLICY: Reimbursable within the provisions of the warranty and repair manual. TIME ALLOWANCE: Labor Operation No. 14-70-17-94 - All 2.5 Hrs. Optional Equipment: 14-70-17-60 - Carter Thermoquad Carburetor 0.5 Hrs. 14-70-17-61 - With Auxiliary A/C - Without Elec. 0.7 Hrs. Rear Window Defroster 14-70-17-62 - Without Auxiliary A/C 0.3 Hrs. 14-70-17-63 - With Auxiliary A/C - Without 0.4 Hrs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2786 Power Windows FAILURE CODE: AM - Authorized Modification Part List VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 22 GALLON FUEL TANK PACKAGE PART NO. 4397611 QTY PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075432 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Seal - Fuel Tank Gauge 3404451 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 36 GALLON FUEL TANK PACKAGE PART NO. 4397612 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075436 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Gasket - Fuel Tank Sending Unit 4115209 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2787 *It may be necessary to order clamp separately on early released packages. PARTS LIST FUEL PRESSURE REGULATOR PACKAGE FOR 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO.4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 PARTS LIST 78 AMP ALTERNATOR PACKAGE FOR 1981-1985 B MODEL TRUCKS WITH 5.2L OR 5.9L ENGINES PACKAGE PART NO. 4397615 QTY. PART NAME PART NO. 1 78 AMP Alternator Assembly - Complete 4111204 1 Alternator Overlay Wiring Harness 4362343 4 Tie Wrap 6015756 1 Gasket - Bulkhead Connector 4055399 FIGURE 4B - Mounting Fuel Resevoir/Filter 1. Fuel Filter/ Reservoir - 4418012 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2788 2. Screw - Self Tapping - 6022777 (2 Req.) 3. Tube Assy - Fuel Pump to Reservoir - 4306968 4. Return Hose & Sleeve Assy - 4418006 5. Hose Clamps - 6500650 (2 Req.) - 1/4" 6. Hose-Fuel Pump Outlet to Reservoir Inlet - 4203576 7. Hose-Reservoir Outlet to Carburetor or Regulator Fuel Tube - 4203576 8. Hose Clamps - 6500651 (4 Req.) - 5/16" Included but not shown: 2 piece Convolute Tubing - 4279993 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1 SCREW & WASHER - 6022254 2 REGULATOR BRACKET - 4418010 3 REGULATOR - 4418OD9 4 TUBE - REGULATOR TO CARB - 4418008 5 TUBE - RESERVOIR HOSE TO REGULATOR - 4418014 6 SCREW (2 EA.) - REGULATOR TO BRACKET - 6033066 7 CLAMP (5116) - 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2794 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2795 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2796 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2797 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2798 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2799 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2800 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2801 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2802 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2803 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2804 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2805 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2806 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2807 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 2808 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock Technical Service Bulletin # 181985A Date: 851201 Fuel System - Vapor Lock Models 1981-1985 Van & Wagon Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 20, 1985 No. 18-19-85 REVISION A P-4782-C This bulletin supersedes Technical Service Bulletin #18-19-85 which should be removed from your files. The model application has been expanded to include 1981 and 1982 model years. SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING TWO PART NUMBERS: Vapor Lock Package With 22 Gallon Fuel Tank PN 4397611 Vapor Lock Package With 36 Gallon Fuel Tank PN 4397612 ADDITIONAL PARTS INFORMATION ON NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 All vehicles equipped with dual air conditioning, without electrically heated rear window defroster, and with 60 amp alternator must order the following package in addition to the vapor lock package. If vehicle is equipped with a 114 amp alternator, do not order this package or make any changes to the charging system. 1 78 AMP Alternator Package PN 4397615 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2813 Refer to parts list for contents of each package. Must be ordered separately: 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. REPAIR PROCEDURE A.Engine Compartment Harness Pn 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1A - ENGINE COMPARTMENT WIRING 3. Remove engine cover. Install the bare eyelet terminal of overlay harness, PN 4362295, to the negative terminal of the ignition coil as shown in Figure 1-A. FIGURE 1B - ENGINE COMPARTMENT WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2814 4. Route and secure the engine overlay harness, PN 4362295, along the existing main engine wiring harness using the existing wiring clips and two tie wraps, PN 6015756 (Figure 1-B). FIGURE 1C - ENGINE COMPARTMENT WIRING 5. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness to the bulkhead connector using the existing wiring clips and three tie wraps, PN 6015756 (Figure 1-C). Loop and tape any excess wire of the engine overlay harness. FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 6. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar multi-purpose grease PN 4318063, and snap into cavity #14 of the engine side of the bulkhead connector (Figure 1-D). B.Instrument Panel Harnesses Pn 4362289, All Models Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2815 FIGURE 2A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) 1. Remove instrument panel left lower trim panel. 2. Insert two bare terminals from instrument panel overlay harness, PN 4362289, into the instrument panel side of the bulkhead connector (Figure 2-A). a. Gray with black tracer wire into cavity #14. b. Dark green wire into cavity #13. INSTRUMENT PANEL WIRING 3. Secure bare eyelet ground terminal (white with black tracer wire) from instrument panel overlay harness, PN 4362289, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). NOTE: CERTAIN VEHICLES ARE ALREADY EQUIPPED WITH THE GROUND SCREW. IF SO, DISCARD THE SUPPLIED SCREW. FIGURE 2C - INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2816 FIGURE 2D - INSTRUMENT PANEL WIRING 4. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-C). Install the extracted terminal (orange wire) into the natural colored 1-way connector supplied with instrument panel overlay harness, PN 4362289. Install the bare terminal (orange wire) from the instrument panel overlay harness, PN 4362289, into the vacated cavity in the ignition switch connector. Reconnect the natural colored 1-way connectors supplied with the instrument panel overlay harness, PN 4362289, and reconnect the ignition switch connectors (Figure 2-C and 2-D). FIGURE 2E - TYPICAL CONTROL MODULE MOUNTING 5. Connect the control (auto shut-down) module, PN 5226640, to the natural colored 8-way connector from instrument panel overlay harness, PN 4362289. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2817 FIGURE 2D - INSTRUMENT PANEL WIRING FIGURE 2F - INSTRUMENT PANEL WIRING 6. Route the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289, to the back of the brake bracket for mating in a later step (Figures 2-B, 2-D, and 2-F). Secure instrument panel overlay harness, PN 4362289, using tie wrap, PN 6015756, to keep it clear of any possible interferences. Only one of the following installation procedures (Step 7) will be used. Take notice of which one applies to the vehicle being repaired. 7. Without Auxiliary Air Conditioning and/or Heater - Jumper Harness PN 4362291 a. Remove instrument panel hood and bezel assembly and remove radio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2818 FIGURE 2D - INSTRUMENT PANEL WIRING b. Route instrument panel jumper harness, PN 4362291, from the back of the brake bracket to the existing 3-way red molded connector. Secure by using existing wiring clips (Figure 2-D). c. Insert the bare bullet terminal (black with white tracer wire) from instrument panel jumper harness, PN 4362291, into the existing 3-way red molded connector from the main instrument panel wiring harness (Figure 2-D). d. Mate the orange colored 1-way connector from instrument panel jumper harness, PN 4362291, to the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). e. Reinstall instrument panel hood and bezel assembly and install radio. FIGURE 2F - INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater and Power Windows - Jumper Harness PN 4362292 a. Disconnect from each other, the two existing brown colored 1-way connectors located near the left instrument panel vent (Figure 2-F). Reconnect these two brown colored 1-way connectors to the two brown colored 1-way connectors from instrument panel jumper harness, PN 4362292 (Figure 2-F). b. Mate the orange colored 1-way connector from the instrument panel jumper harness, PN 4362292, to the orange colored 1-way connector from instrument panel overlay harness, PN 4362289 (Figure 2-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2819 INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater Without Power Windows - Relay Harness PN 4362290 a. Remove instrument panel hood and bezel assembly. Remove radio. b. Install the ignition switch protection relay, PN 4162597, to the back of the brake bracket (mounting location shown in Figure 2-B) and attach instrument panel relay harness, PN 4362290, to relay. c. Secure bare eyelet ground terminal (white wire) from instrument panel relay harness, PN 4362290, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING d. Route the dark blue wire from the instrument panel relay harness, PN 4362290 to the existing 3-way red molded connector using existing wiring clips. Insert bullet terminal (dark blue wire) into red molded connector (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2820 INSTRUMENT PANEL WIRING e. Insert bare bullet terminal (red wire) from instrument panel relay harness, PN 4362290, into the existing 3-way yellow molded connector from the main instrument panel wiring harness (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING f. Mate the orange colored 1-way connector from instrument panel relay harness, PN 4362290, to the colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). g. Install the instrument panel left lower trim panel, instrument panel hood, bezel assembly and radio. C.In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Feed red and yellow molds of body wiring harness, PN 4362293, through slot in the crossmember. Remove existing screw for gauge unit ground. Install eyelet terminal of harness, PN 4362293 (and ground eyelet terminal of 36 gallon tank gauge/pump unit) and torque ground screw to 36 inch pounds. CAUTION: GROUND SCREW MUST BE TIGHTENED SECURELY TO OPERATE ELECTRIC PUMP AND GAUGE UNIT. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2821 FIGURE 3A - BODY WIRING FIGURE 3B - BODY WIRING Install red mold of body harness, PN 4362293, onto red stud of gauge/pump unit. Install yellow mold of harness, PN 4362293, onto black stud of gauge/pump unit (figure 3-a or 3-b). Install molded blade terminal of harness, PN 4362293, onto blade terminal of 22 gallon gauge unit only. NOTE: PREVIOUS GAUGE UNIT GROUND WILL NOT BE USED ON 22 GALLON GAUGE/PUMP UNIT. ON 36 GALLON GAUGE PUMP UNIT, THE GROUND WIRE ON HARNESS PN 4362293 WILL NOT BE USED. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. Set aside the rest of harness, PN 4362293, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. D.Body Wiring Harness Pn 4362293 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2822 FIGURE 3C - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2823 FIGURE 3-F - BODY WIRING 1. Vehicles With 36 Gallon Tank Route harness, PN 4362293, to the right (passenger) side of vehicle along the fuel line tubes and tie wrap (1). At right frame rail, route harness forward to next crossmember (Figures 3-C and 3-E). Tie wrap harness in three (3) places. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2824 FIGURE 3D - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2825 FIGURE 3-F - BODY WIRING Vehicles With 22 Gallon Tank Route harness, PN 4362293, along right frame rail following brake lines (Figures 3-D and 3-E). Tie wrap in two (2) places. NOTE: HARNESS MUST BE ABOVE SHOCK STRUT WITH EITHER 36 OR 22 GALLON TANK. 2. At crossmember, route harness to the left rail following existing brake lines and tie wrap in two (2) places. At left rail, route harness forward through access holes following existing brake lines. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2826 FIGURE 3-F - BODY WIRING NOTE: HARNESS SHOULD BE TIGHT IN THIS AREA THE WRAP IN FOUR (4) PLACES (FIGURE 3-E). 3. At engine compartment, route harness through existing speedometer cable clips to bulkhead connector. If excess wiring exists; loop, tie wrap (2), and install into existing clip (Figure 3-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2827 FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 4. Plug bare terminal of harness, PN 4362293, into cavity #13 of the bulkhead connector (Figure 1-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2828 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2829 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2830 FIGURE 9 - ELECTRIC FUEL PUMP WIRING DIAGRAMW/AUX A/C & HEATER-W/O POWER WINDOWS 5. For all vehicles except those which require a 78 amp alternator package: Reinstall instrument panel side, then engine compartment side of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURES 7, 8, OR 9 FOR OVERALL WIRING DIAGRAMS. E.Engine Compartment Fuel Reservoir/Filter Lnstallation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2831 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER 1. Using template, PN 4418011, mark and drill (from engine side of passenger side chassis rail) two (2) holes .290" diameter (L size drill) as shown in Figure 4-A. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2832 FIGURE 4B - Mounting Fuel Resevoir/Filter 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. NOTE: RUBBER SPLASH SHIELD MAY HAVE TO BE CUT OUT AROUND FUEL RESERVOIR. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube, PN 4306968 (Figure 4-B). 4. Install return hose assembly, PN 4418006, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end (Figure 4-B). 5. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 42O3576. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2833 FIGURE 4B - Mounting Fuel Resevoir/Filter 6. Install one 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the fuel pump outlet tube to the reservoir/filter inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). 7. Install the other 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 8. Tighten all hose clamps to 10 inch pounds. FIGURE 10 9. Type Authorized Modification Label, PN 4275086, as shown in Figure 10 and attach near VECI label. 10. For all models except 1981-1984 equipped with Carter Thermoquad 4BBL carburetor or dual air conditioning units without electrically Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2834 heated rear window defroster. Reconnect battery. Start the engine, and inspect the entire system for fuel leaks and proper wire and hose routing. 11. Reinstall engine cover. F.1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (Pn 4397 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6O22254, (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT, AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6O22254. THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2835 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference with nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose-to-regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. For all models except those equipped with dual air conditioning units, without electrically heated rear window defroster and with 60 amp alternator: 6. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 7. Reinstall engine cover. G.Vehicles Equipped With Dual Air Conditioning Units, Without Electrically Heated Rear Defroster, and With 60 Amp Alternator. I Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2836 HEADLAMP AND DASH WIRING ASSEMBLY 1. Disconnect the battery positive lead (single in-line connection) from the headlamp and dash wiring assembly (Figure 6-A). FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 2. Remove the following wires from the engine compartment side of the bulkhead connector (Figure 6-B). a. Red wire from cavity #39 (ammeter). b. Black wire from cavity #33 (ammeter). Cut off the terminals and wrap tape around each end of both wires to insure that shorting cannot occur. Then tape the wrapped wires back against the main harness. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2837 FIGURE 6-C - 78 AMP ALTERNATOR WIRING 3. Remove the alternator output wire (heavy gauge) from the 60 amp alternator (Figure 6-C). Cut the wire off leaving approximately three (3) inches of wire extending out of the main harness. Tape the end of the lead thoroughly. Then fold and tape the lead back against the main harness to prevent shorting. 4. Remove 60 amp alternator assembly and install 78 amp alternator assembly, PN 4111204, per the service manual alternator replacement procedure. HEADLAMP AND DASH WIRING ASSEMBLY Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2838 FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 5. Beginning at the bulkhead, route and connect the wiring assembly, PN 4362343, as shown in Figure 6-A. Use the existing clip for main harness and tie wrap with three (3) tie wraps, PN 6015756. Insert the two bare terminals from alternator overlay wiring harness, PN 4362343, as shown in Figure 6-B as follows: NOTE: THE 4362343 ALTERNATOR OVERLAY HARNESS WAS MANUFACTURED WITH THE RED AND BLACK WIRES REVERSED. THEREFORE, IT WILL BE NECESSARY TO INSTALL THE BLACK WIRE (LABELED RED) INTO CAVITY #39 (RED WIRE PREVIOUSLY REMOVED), AND THE RED WIRE (LABELED BLACK) INTO CAVITY #33 (BLACK WIRE PREVIOUSLY REMOVED). FAILURE TO REVERSE THESE TWO WIRES WILL RESULT IN THE AMMETER SHOWING THE OPPOSITE CHARGE INDICATION. a. Red wire into cavity #33 (ammeter) - (labeled as black wire). b. Black wire into cavity #39 (ammeter) - (labeled as red wire). 6. Install wiring assembly, PN 4362343, alternator output terminal to new 78 amp alternator. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2839 FIGURE 6A1 7. Connect the battery positive lead and the headlamp and dash wiring assembly lead to those of the alternator overlay wiring assembly, PN 4362343, as shown in circled view of Figure 6-A. 8. Reinstall instrument panel half, then engine compartment half of bulkhead connector and torque to 40 inch pounds. 9. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 10. Reinstall engine cover. POLICY: Reimbursable within the provisions of the warranty and repair manual. TIME ALLOWANCE: Labor Operation No. 14-70-17-94 - All 2.5 Hrs. Optional Equipment: 14-70-17-60 - Carter Thermoquad Carburetor 0.5 Hrs. 14-70-17-61 - With Auxiliary A/C - Without Elec. 0.7 Hrs. Rear Window Defroster 14-70-17-62 - Without Auxiliary A/C 0.3 Hrs. 14-70-17-63 - With Auxiliary A/C - Without 0.4 Hrs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2840 Power Windows FAILURE CODE: AM - Authorized Modification Part List VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 22 GALLON FUEL TANK PACKAGE PART NO. 4397611 QTY PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075432 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Seal - Fuel Tank Gauge 3404451 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 36 GALLON FUEL TANK PACKAGE PART NO. 4397612 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075436 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Gasket - Fuel Tank Sending Unit 4115209 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2841 *It may be necessary to order clamp separately on early released packages. PARTS LIST FUEL PRESSURE REGULATOR PACKAGE FOR 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO.4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 PARTS LIST 78 AMP ALTERNATOR PACKAGE FOR 1981-1985 B MODEL TRUCKS WITH 5.2L OR 5.9L ENGINES PACKAGE PART NO. 4397615 QTY. PART NAME PART NO. 1 78 AMP Alternator Assembly - Complete 4111204 1 Alternator Overlay Wiring Harness 4362343 4 Tie Wrap 6015756 1 Gasket - Bulkhead Connector 4055399 FIGURE 4B - Mounting Fuel Resevoir/Filter 1. Fuel Filter/ Reservoir - 4418012 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 2842 2. Screw - Self Tapping - 6022777 (2 Req.) 3. Tube Assy - Fuel Pump to Reservoir - 4306968 4. Return Hose & Sleeve Assy - 4418006 5. Hose Clamps - 6500650 (2 Req.) - 1/4" 6. Hose-Fuel Pump Outlet to Reservoir Inlet - 4203576 7. Hose-Reservoir Outlet to Carburetor or Regulator Fuel Tube - 4203576 8. Hose Clamps - 6500651 (4 Req.) - 5/16" Included but not shown: 2 piece Convolute Tubing - 4279993 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1 SCREW & WASHER - 6022254 2 REGULATOR BRACKET - 4418010 3 REGULATOR - 4418OD9 4 TUBE - REGULATOR TO CARB - 4418008 5 TUBE - RESERVOIR HOSE TO REGULATOR - 4418014 6 SCREW (2 EA.) - REGULATOR TO BRACKET - 6033066 7 CLAMP (5116) - 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2845 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2846 Fuel Gauge Sender: Electrical Diagrams Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2847 Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 2848 Fig. 15 Fuel Gauge & Seatbelt Warning System Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Page 2849 Fuel Gauge Sender: Testing and Inspection A hinged float arm in the fuel tank contacts a variable resistor in the gauge sending unit. The varying resistance in the fuel gauge circuit registers on the instrument panel gauge. Resistance in the circuit is lowest when the fuel tank is full and float arm is raised. The resulting high current flow causes the instrument panel gauge to indicate Full. TROUBLESHOOTING 1. Disconnect electrical connector from fuel tank sending unit and attach connector to a known good sending unit. 2. Connect a jumper wire between sending unit fuel pickup tube and a good ground. 3. Secure sending unit float arm in the empty stop position and turn ignition On. Within two minutes, the gauge should read Empty, plus one pointer width or minus two pointer widths. 4. Move float arm and secure in the full stop position. Within two minutes, the gauge should read Full, plus two pointer widths, or minus one pointer width. 5. If fuel gauge does not operate as specified, check the following: a. Wiring and electrical connections between sending unit and connector. b. Wiring and electrical connections between connector and printed circuit board terminals. c. Circuit continuity between printed circuit board terminals and gauge terminals. d. Voltage limiter performance. 6. If fuel gauge operates as specified with known good sending unit, check fuel tank and original sending unit as follows: a. Remove sending unit from fuel tank. b. Connect sending unit wire and jumper wire as previously described. c. If fuel gauge now operates as specified, check sending unit for damage, obstructions or improper installation and correct as necessary. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Adjustments Idle Speed Control (Linkage): Adjustments VACUUM THROTTLE POSITIONER, ADJUST 1. Start engine and allow to idle in neutral, then accelerate engine to above 2000 RPM to make sure that throttle positioner operates and can maintain its position when a hand load is applied. If not, determine cause of malfunction and correct as necessary as described under ``Testing'' procedure before proceeding further. 2. Accelerate engine to about 2500 RPM then loosen positioner adjustment lock nut and rotate positioner assembly until it just contacts throttle lever. 3. Release throttle and adjust positioner to decrease engine speed until a sudden drop in speed occurs (over 1000 RPM). Continue adjusting positioner in decreasing direction 1/4 turn and tighten lock nut. 4. Accelerate engine to about 2500 RPM and release throttle. If engine speed returns to normal idle, throttle positioner is properly adjusted. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2856 Idle Speed/Throttle Actuator - Electronic: Locations Engine Mounted Switches & Sensors. On Carburetor Applicable to: V8 Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 2857 Idle Speed/Throttle Actuator - Electronic: Description and Operation Fig. 46 Vacuum throttle positioner system Some vehicles are equipped with a throttle positioner system to prevent unburned hydrocarbon emissions through the exhaust system when the engine is decelerated from a high RPM. This system consists of an electronic speed switch, an electrically controlled vacuum solenoid valve and a vacuum actuated throttle positioner, Fig. 46. The electronic speed switch senses ignition pulses from the 5 ohm ballast resistor terminal connected to the ignition control unit. When engine speed exceeds 2000 RPM, the speed switch allows vacuum to energize the throttle positioner. When the positioner is energized, a throttle stop provided, will prevent the engine from returning to the idle position. When the throttle is released, it will return the idle to 1750 RPM. As the engine decelerates, the electronic speed switch senses when the engine speed drops below 2000 RPM and de-energizes the throttle positioner. This permits the throttle to return to the normal idle stop position and the engine will continue to decelerate to the idle speed. This operation positions the throttle partially open (1750 RPM) whenever the engine decelerates from a speed above 2000 RPM to a speed just below 2000 RPM, thus providing sufficient air flow through the engine to dilute the air/fuel mixture. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Up Control Valve > Component Information > Adjustments Idle Up Control Valve: Adjustments VACUUM THROTTLE POSITIONER, ADJUST 1. Start engine and allow to idle in neutral, then accelerate engine to above 2000 RPM to make sure that throttle positioner operates and can maintain its position when a hand load is applied. If not, determine cause of malfunction and correct as necessary as described under ``Testing'' procedure before proceeding further. 2. Accelerate engine to about 2500 RPM then loosen positioner adjustment lock nut and rotate positioner assembly until it just contacts throttle lever. 3. Release throttle and adjust positioner to decrease engine speed until a sudden drop in speed occurs (over 1000 RPM). Continue adjusting positioner in decreasing direction 1/4 turn and tighten lock nut. 4. Accelerate engine to about 2500 RPM and release throttle. If engine speed returns to normal idle, throttle positioner is properly adjusted. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Choke Temperature Control Switch > Component Information > Locations Choke Temperature Control Switch: Locations Upper RH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Intake Air Temperature (IAT) Sensor <--> [Throttle Body Temperature Sensor] > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Carburetor Switch <--> [Throttle Full Close Switch] > Component Information > Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Carburetor Switch <--> [Throttle Full Close Switch] > Component Information > Locations > Page 2871 Carburetor Switch: Description and Operation Fig. 4 Switches & sensors location. V8 engine The carburetor switch, Fig. 4, is located on the end of the idle stop and it signals the computer when the engine is at idle. Whenever the curb idle screw touches the carburetor switch, there will be no additional advance from the vacuum transducer or changing of the carburetor air fuel ratio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2876 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Intake Air Temperature (IAT) Sensor <--> [Throttle Body Temperature Sensor] > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor Switch <--> [Throttle Full Close Switch] > Component Information > Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor Switch <--> [Throttle Full Close Switch] > Component Information > Locations > Page 2884 Carburetor Switch: Description and Operation Fig. 4 Switches & sensors location. V8 engine The carburetor switch, Fig. 4, is located on the end of the idle stop and it signals the computer when the engine is at idle. Whenever the curb idle screw touches the carburetor switch, there will be no additional advance from the vacuum transducer or changing of the carburetor air fuel ratio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2889 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Timing Marks and Indicators: Diagrams TIMING MARK 1981-85 5.2L & 5.9L Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams > Page 2901 TIMING MARK 1981-90 Some 5.2L & 5.9L Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Resistor <--> [Ignition Ballast Resistor] > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Resistor <--> [Ignition Ballast Resistor] > Component Information > Specifications > Page 2905 Ignition Resistor: Locations Ballast Resistor Left side of fire wall, engine compartment. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2910 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2915 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control Crankshaft Position Sensor: Service and Repair RWD W/ Electronic Spark Control Removal & Installation Removal 1. Disconnect vacuum line at distributor, if equipped. 2. Disconnect distributor pickup lead(s) at wiring harness connector, then remove distributor cap. 3. Mark position of rotor on distributor body and engine block surface so that distributor can be installed in the same position. 4. Remove hold-down and/or bolt and lift distributor from engine. Installation 1. If engine was cranked after distributor was removed from engine, rotate crankshaft to bring No. 1 piston up on its compression stroke and align timing mark on crankshaft pulley with ``O'' (TDC) mark on timing cover. 2. With distributor gasket or O-ring in place, hold distributor over mounting pad. 3. Turn rotor to a position just ahead of the No. 1 distributor cap terminal. 4. Install distributor, engaging distributor gear with camshaft drive gear on 6 cylinder engines. On V-8 engines, engage tang of distributor shaft with slot in oil pump drive gear. With distributor fully seated on engine, rotor should be under No. 1 cap terminal. 5. Install distributor hold-down and/or bolt, distributor cap, pickup lead(s) and vacuum line. 6. Adjust ignition timing to specifications found in the Tune Up section. Distributor Shaft & Bushing Wear Test 1. Remove distributor from vehicle and clamp distributor in a vise. Use extreme caution not to damage distributor. 2. Attach a dial indicator to housing so plunger rests against reluctor sleeve. 3. Place a wire loop around reluctor sleeve and hook a spring scale on the other end of the loop. Apply a 1-1/2 lb. pull toward dial indicator. Apply a 1 lb. pull away from dial indicator and read movement on indicator. 4. Movement must not exceed .006 inch. If movement exceeds limit, replace either housing or shaft to bring movement back within tolerance. Distributor Disassembly 1. Remove rotor and vacuum advance unit, if equipped Fig. 14. 2. Remove reluctor by prying up from bottom of reluctor using two screwdrivers with a maximum blade width of 7/16 in. Use care not to damage or distort reluctor teeth. 3. Remove two screws and lockwashers attaching lower plate to distributor housing, then lift out lower plate, upper plate and pickup coil as an assembly. Do not remove distributor cap clamp springs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 2918 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 4. On eight cylinder units, if distributor housing, shaft, reluctor sleeve or governor weights are to be replace, proceed as follows: a. Remove distributor shaft retaining pin and slide retainer off end of shaft. b. If necessary, use a file to clean burrs from around pin hole area on shaft, then remove lower thrust washer. c. Push shaft upward and remove from distributor housing. Distributor Assembly Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 2919 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 1. Lubricate and test operation of governor weights. Inspect weight springs for distortion and bearing surfaces and pins for damage. 2. Lubricate upper thrust washer and install onto shaft. Install shaft into housing. 3. On eight cylinder units, install distributor shaft retainer and pin, Fig. 14. 4. On all units, install lower plate, upper plate and pickup coil assembly. 5. Attach vacuum advance unit to pickup plate, then install vacuum advance unit attaching screws and washers. 6. Position reluctor keeper pin into place on reluctor sleeve, then slide reluctor down reluctor sleeve and press firmly into position. Install keeper pin. 7. Lubricate felt pad located in top of reluctor sleeve with one drop of light engine oil, then install rotor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 2920 Crankshaft Position Sensor: Service and Repair RWD W/O Electronic Spark Control Removal & Installation Removal 1. Disconnect vacuum line at distributor, if equipped. 2. Disconnect distributor pickup lead(s) at wiring harness connector, then remove distributor cap. 3. Mark position of rotor on distributor body and engine block surface so that distributor can be installed in the same position. 4. Remove hold-down and/or bolt and lift distributor from engine. Installation 1. If engine was cranked after distributor was removed from engine, rotate crankshaft to bring No. 1 piston up on its compression stroke and align timing mark on crankshaft pulley with ``O'' (TDC) mark on timing cover. 2. With distributor gasket or O-ring in place, hold distributor over mounting pad. 3. Turn rotor to a position just ahead of the No. 1 distributor cap terminal. 4. Install distributor, engaging distributor gear with camshaft drive gear on 6 cylinder engines. On V-8 engines, engage tang of distributor shaft with slot in oil pump drive gear. With distributor fully seated on engine, rotor should be under No. 1 cap terminal. 5. Install distributor hold-down and/or bolt, distributor cap, pickup lead(s) and vacuum line. 6. Adjust ignition timing to specifications found in the Tune Up section. Distributor Shaft & Bushing Wear Test 1. Remove distributor from vehicle and clamp distributor in a vise. Use extreme caution not to damage distributor. 2. Attach a dial indicator to housing so plunger rests against reluctor sleeve. 3. Place a wire loop around reluctor sleeve and hook a spring scale on the other end of the loop. Apply a 1-1/2 lb. pull toward dial indicator. Apply a 1 lb. pull away from dial indicator and read movement on indicator. 4. Movement must not exceed .006 inch. If movement exceeds limit, replace either housing or shaft to bring movement back within tolerance. Distributor Disassembly 1. Remove rotor and vacuum advance unit, if equipped Fig. 14. 2. Remove reluctor by prying up from bottom of reluctor using two screwdrivers with a maximum blade width of 7/16 in. Use care not to damage or distort reluctor teeth. 3. Remove two screws and lockwashers attaching lower plate to distributor housing, then lift out lower plate, upper plate and pickup coil as an assembly. Do not remove distributor cap clamp springs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 2921 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 4. On eight cylinder units, if distributor housing, shaft, reluctor sleeve or governor weights are to be replace, proceed as follows: a. Remove distributor shaft retaining pin and slide retainer off end of shaft. b. If necessary, use a file to clean burrs from around pin hole area on shaft, then remove lower thrust washer. c. Push shaft upward and remove from distributor housing. Distributor Assembly Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 2922 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 1. Lubricate and test operation of governor weights. Inspect weight springs for distortion and bearing surfaces and pins for damage. 2. Lubricate upper thrust washer and install onto shaft. Install shaft into housing. 3. On eight cylinder units, install distributor shaft retainer and pin, Fig. 14. 4. On all units, install lower plate, upper plate and pickup coil assembly. 5. Attach vacuum advance unit to pickup plate, then install vacuum advance unit attaching screws and washers. 6. Position reluctor keeper pin into place on reluctor sleeve, then slide reluctor down reluctor sleeve and press firmly into position. Install keeper pin. 7. Lubricate felt pad located in top of reluctor sleeve with one drop of light engine oil, then install rotor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Vacuum Advance Unit <--> [Distributor Advance Unit] > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Vacuum Advance Unit <--> [Distributor Advance Unit] > Component Information > Specifications > Page 2927 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Vacuum Control > Component Information > Locations Distributor Vacuum Control: Locations Orifice Spark Advance Control (OSAC) Valve Location. In Air Cleaner Housing Applicable to: V8 Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Power Module <--> [Electronic Spark Control Module] > Component Information > Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Power Module <--> [Electronic Spark Control Module] > Component Information > Locations > Page 2934 Power Module: Description and Operation The spark control computer controls the air fuel ratio of the carburetor and the ignition timing. The computer receives signals from various sensors and processes them to determine the air fuel ratio of the carburetor and ignition timing. There are as many as six types of sensors which can be used to supply the spark control computer with the necessary information needed to fire the spark plugs at the precise moment and, with the feedback carburetor, change the air-fuel ratio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service and Repair Ignition Cable: Service and Repair REMOVAL AND INSTALLATION Cable Removal CAUTION: When disconnecting a high voltage cable from a spark plug or from the distributor cap, twist the rubber boot slightly (1/2 turn) to break it loose. Grasp the boot (not the cable) and pull it off with a steady, even force. Engine Firing Order Install cables into the proper engine cylinder firing order. When replacing the spark plug and coil cables, route the cables correctly and secure in the proper retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could also cause cross ignition of the plugs or short circuit the cables to ground. When installing new cables, make sure a positive connection is made. A snap should be felt when a good connection is made between the plug cable and the distributor cap tower. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 2941 Ignition Coil: Locations Electronic Ignition System Components Upper RH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Specifications > Electrical Specifications Ignition Control Module: Electrical Specifications Part No. Spark Advance Test Electronic EGR Time Delay Electronic Throttle Control 4289601 38 +/- 4 deg at 2000 rpm 60 min 90 sec Note: After start or 2 sec. after throttle close condition. 4289603 33 +/- 4 deg at 2000 rpm 45 min 60 sec Note: After start or 1 sec. after throttle close condition. 4289613 30 +/- 4 deg at 2000 rpm 60 min 90 sec Note: After start or 1 sec. after throttle close condition. 4289615 30 +/- 4 deg at 2000 rpm 28 min 60 sec Note: After start or 2 sec. after throttle close condition. 4289617 30 +/- 4 deg at 2000 rpm 65 min 60 sec 4289621 37 +/- 4 deg at 2000 rpm 60 min --4289637 34 +/- 4 deg at 2000 rpm 25 min 25 sec Note: After start or 1 sec. after throttle close position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Specifications > Electrical Specifications > Page 2946 Ignition Control Module: Mechanical Specifications Part No. Spark Advance Test Electronic EGR Time Delay Electronic Throttle Control 4289601 38 +/- 4 deg at 2000 rpm 60 min 90 sec Note: After start or 2 sec. after throttle close condition. 4289603 33 +/- 4 deg at 2000 rpm 45 min 60 sec Note: After start or 1 sec. after throttle close condition. 4289613 30 +/- 4 deg at 2000 rpm 60 min 90 sec Note: After start or 1 sec. after throttle close condition. 4289615 30 +/- 4 deg at 2000 rpm 28 min 60 sec Note: After start or 2 sec. after throttle close condition. 4289617 30 +/- 4 deg at 2000 rpm 65 min 60 sec 4289621 37 +/- 4 deg at 2000 rpm 60 min --4289637 34 +/- 4 deg at 2000 rpm 25 min 25 sec Note: After start or 1 sec. after throttle close position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2949 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Component Locations Detonation (Knock) Sensor: Component Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Component Locations > Page 2954 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Page 2955 Detonation (Knock) Sensor: Description and Operation Fig. 12 Detonation sensor location. V8 engine The detonation sensor, Fig. 12, is used on V8 engines only and is located in the intake manifold. It signals the computer when detonation occurs so that the ignition timing can be retarded. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Pick-Up Coil, Ignition > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Pick-Up Coil, Ignition > Component Information > Specifications > Page 2959 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Pick-Up Coil, Ignition > Component Information > Specifications > Page 2960 Pick-Up Coil: Description and Operation This coil supplies the basic timing signal to the computer. The computer also uses this signal to determine engine RPM, location of piston during compression stroke and when engine is in cranking mode. In-line six cylinder and V8 engines can use one or two pick up coils depending on application. The start pick up coil, located on the distributor, signals the computer to fire the spark plugs at a fixed amount of advance during cranking only. The amount of advance is determined by the position of the start pick up coil. The run pick up coil is used by the computer to monitor engine speed and crankshaft position after the engine has started. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Pick-Up Coil, Ignition > Component Information > Service and Repair > RWD With Electronic Spark Control Pick-Up Coil: Service and Repair RWD With Electronic Spark Control Fig. 17 Air gap adjustment. Distributors equipped with dual pickup shown. Distributors with single pickup similar 1. With distributor removed from vehicle, perform Steps 1 to 3 as outlined in Distributor Disassemble. 2. Remove pickup coil and upper plate by depressing retainer clip and moving it away from mounting stud. Pickup coil cannot be removed from upper plate. 3. Lightly lubricate upper plate pivot pin and lower plate support pins with distributor lubricant. Install upper plate pivot pin through smallest hole in lower plate and install retainer clip. The upper plate must ride on the support pins on the lower plate. 4. Install lower and upper plates and pickup coil as an assembly and install distributor into vehicle. On dual pickup distributors, the start pickup may be identified by a two prong male connector and the run pickup may be identified by a male-female plug, Fig. 17. 5. To set air gap on all single pickup distributors and start pickup of dual pickup distributors, align one reluctor tooth with pickup pole and install a .006 inch non-magnetic feeler gauge between reluctor tooth and pickup pole, Figs. 17 and 18. Rotate pickup coil until contact is made between reluctor tooth, feeler gauge and pickup pole. Tighten pickup coil hold down screw and remove feeler gauge. The feeler gauge should be removed without force. If it cannot, readjust gap. 6. To set air gap on run pickup of dual pickup distributors, first adjust start pickup as described in step 5, then adjust run pickup as described in step 5. Use a .012 inch non-magnetic feeler gauge to adjust run pickup air gap. 7. Perform a second gap check using a .008 inch feeler gauge on all single pickup distributors and on start pickup of dual pickup distributor or a .014 inch feeler gauge on run pickup of dual pickup distributors. Do not force feeler gauge between reluctor tooth and pickup pole as it is possible to do so. The feeler gauge should not be able to fit between the reluctor tooth and pickup pole if air gap is correctly set. Apply vacuum to vacuum control unit. Pickup should not contact reluctor tooth. Readjust air gap if contact occurs. If pickup contacts reluctor teeth on one side of shaft only, the distributor shaft is most likely bent and shaft replacement required. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Pick-Up Coil, Ignition > Component Information > Service and Repair > RWD With Electronic Spark Control > Page 2963 Pick-Up Coil: Service and Repair RWD Without Electronic Spark Control Fig. 17 Air gap adjustment. Distributors equipped with dual pickup shown. Distributors with single pickup similar 1. With distributor removed from vehicle, perform Steps 1 to 3 as outlined in Distributor Disassemble. 2. Remove pickup coil and upper plate by depressing retainer clip and moving it away from mounting stud. Pickup coil cannot be removed from upper plate. 3. Lightly lubricate upper plate pivot pin and lower plate support pins with distributor lubricant. Install upper plate pivot pin through smallest hole in lower plate and install retainer clip. The upper plate must ride on the support pins on the lower plate. 4. Install lower and upper plates and pickup coil as an assembly and install distributor into vehicle. On dual pickup distributors, the start pickup may be identified by a two prong male connector and the run pickup may be identified by a male-female plug, Fig. 17. 5. To set air gap on all single pickup distributors and start pickup of dual pickup distributors, align one reluctor tooth with pickup pole and install a .006 inch non-magnetic feeler gauge between reluctor tooth and pickup pole, Figs. 17 and 18. Rotate pickup coil until contact is made between reluctor tooth, feeler gauge and pickup pole. Tighten pickup coil hold down screw and remove feeler gauge. The feeler gauge should be removed without force. If it cannot, readjust gap. 6. To set air gap on run pickup of dual pickup distributors, first adjust start pickup as described in step 5, then adjust run pickup as described in step 5. Use a .012 inch non-magnetic feeler gauge to adjust run pickup air gap. 7. Perform a second gap check using a .008 inch feeler gauge on all single pickup distributors and on start pickup of dual pickup distributor or a .014 inch feeler gauge on run pickup of dual pickup distributors. Do not force feeler gauge between reluctor tooth and pickup pole as it is possible to do so. The feeler gauge should not be able to fit between the reluctor tooth and pickup pole if air gap is correctly set. Apply vacuum to vacuum control unit. Pickup should not contact reluctor tooth. Readjust air gap if contact occurs. If pickup contacts reluctor teeth on one side of shaft only, the distributor shaft is most likely bent and shaft replacement required. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Power Module <--> [Electronic Spark Control Module] > Component Information > Locations Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Power Module <--> [Electronic Spark Control Module] > Component Information > Locations > Page 2968 Power Module: Description and Operation The spark control computer controls the air fuel ratio of the carburetor and the ignition timing. The computer receives signals from various sensors and processes them to determine the air fuel ratio of the carburetor and ignition timing. There are as many as six types of sensors which can be used to supply the spark control computer with the necessary information needed to fire the spark plugs at the precise moment and, with the feedback carburetor, change the air-fuel ratio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Specifications > Electrical Specifications Ignition Control Module: Electrical Specifications Part No. Spark Advance Test Electronic EGR Time Delay Electronic Throttle Control 4289601 38 +/- 4 deg at 2000 rpm 60 min 90 sec Note: After start or 2 sec. after throttle close condition. 4289603 33 +/- 4 deg at 2000 rpm 45 min 60 sec Note: After start or 1 sec. after throttle close condition. 4289613 30 +/- 4 deg at 2000 rpm 60 min 90 sec Note: After start or 1 sec. after throttle close condition. 4289615 30 +/- 4 deg at 2000 rpm 28 min 60 sec Note: After start or 2 sec. after throttle close condition. 4289617 30 +/- 4 deg at 2000 rpm 65 min 60 sec 4289621 37 +/- 4 deg at 2000 rpm 60 min --4289637 34 +/- 4 deg at 2000 rpm 25 min 25 sec Note: After start or 1 sec. after throttle close position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Specifications > Electrical Specifications > Page 2973 Ignition Control Module: Mechanical Specifications Part No. Spark Advance Test Electronic EGR Time Delay Electronic Throttle Control 4289601 38 +/- 4 deg at 2000 rpm 60 min 90 sec Note: After start or 2 sec. after throttle close condition. 4289603 33 +/- 4 deg at 2000 rpm 45 min 60 sec Note: After start or 1 sec. after throttle close condition. 4289613 30 +/- 4 deg at 2000 rpm 60 min 90 sec Note: After start or 1 sec. after throttle close condition. 4289615 30 +/- 4 deg at 2000 rpm 28 min 60 sec Note: After start or 2 sec. after throttle close condition. 4289617 30 +/- 4 deg at 2000 rpm 65 min 60 sec 4289621 37 +/- 4 deg at 2000 rpm 60 min --4289637 34 +/- 4 deg at 2000 rpm 25 min 25 sec Note: After start or 1 sec. after throttle close position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions Ignition Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2976 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Spark Control Relay > Component Information > Locations Spark Control Relay: Locations Electronic Ignition System Components On Firewall Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2985 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2990 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control Crankshaft Position Sensor: Service and Repair RWD W/ Electronic Spark Control Removal & Installation Removal 1. Disconnect vacuum line at distributor, if equipped. 2. Disconnect distributor pickup lead(s) at wiring harness connector, then remove distributor cap. 3. Mark position of rotor on distributor body and engine block surface so that distributor can be installed in the same position. 4. Remove hold-down and/or bolt and lift distributor from engine. Installation 1. If engine was cranked after distributor was removed from engine, rotate crankshaft to bring No. 1 piston up on its compression stroke and align timing mark on crankshaft pulley with ``O'' (TDC) mark on timing cover. 2. With distributor gasket or O-ring in place, hold distributor over mounting pad. 3. Turn rotor to a position just ahead of the No. 1 distributor cap terminal. 4. Install distributor, engaging distributor gear with camshaft drive gear on 6 cylinder engines. On V-8 engines, engage tang of distributor shaft with slot in oil pump drive gear. With distributor fully seated on engine, rotor should be under No. 1 cap terminal. 5. Install distributor hold-down and/or bolt, distributor cap, pickup lead(s) and vacuum line. 6. Adjust ignition timing to specifications found in the Tune Up section. Distributor Shaft & Bushing Wear Test 1. Remove distributor from vehicle and clamp distributor in a vise. Use extreme caution not to damage distributor. 2. Attach a dial indicator to housing so plunger rests against reluctor sleeve. 3. Place a wire loop around reluctor sleeve and hook a spring scale on the other end of the loop. Apply a 1-1/2 lb. pull toward dial indicator. Apply a 1 lb. pull away from dial indicator and read movement on indicator. 4. Movement must not exceed .006 inch. If movement exceeds limit, replace either housing or shaft to bring movement back within tolerance. Distributor Disassembly 1. Remove rotor and vacuum advance unit, if equipped Fig. 14. 2. Remove reluctor by prying up from bottom of reluctor using two screwdrivers with a maximum blade width of 7/16 in. Use care not to damage or distort reluctor teeth. 3. Remove two screws and lockwashers attaching lower plate to distributor housing, then lift out lower plate, upper plate and pickup coil as an assembly. Do not remove distributor cap clamp springs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 2993 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 4. On eight cylinder units, if distributor housing, shaft, reluctor sleeve or governor weights are to be replace, proceed as follows: a. Remove distributor shaft retaining pin and slide retainer off end of shaft. b. If necessary, use a file to clean burrs from around pin hole area on shaft, then remove lower thrust washer. c. Push shaft upward and remove from distributor housing. Distributor Assembly Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 2994 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 1. Lubricate and test operation of governor weights. Inspect weight springs for distortion and bearing surfaces and pins for damage. 2. Lubricate upper thrust washer and install onto shaft. Install shaft into housing. 3. On eight cylinder units, install distributor shaft retainer and pin, Fig. 14. 4. On all units, install lower plate, upper plate and pickup coil assembly. 5. Attach vacuum advance unit to pickup plate, then install vacuum advance unit attaching screws and washers. 6. Position reluctor keeper pin into place on reluctor sleeve, then slide reluctor down reluctor sleeve and press firmly into position. Install keeper pin. 7. Lubricate felt pad located in top of reluctor sleeve with one drop of light engine oil, then install rotor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 2995 Crankshaft Position Sensor: Service and Repair RWD W/O Electronic Spark Control Removal & Installation Removal 1. Disconnect vacuum line at distributor, if equipped. 2. Disconnect distributor pickup lead(s) at wiring harness connector, then remove distributor cap. 3. Mark position of rotor on distributor body and engine block surface so that distributor can be installed in the same position. 4. Remove hold-down and/or bolt and lift distributor from engine. Installation 1. If engine was cranked after distributor was removed from engine, rotate crankshaft to bring No. 1 piston up on its compression stroke and align timing mark on crankshaft pulley with ``O'' (TDC) mark on timing cover. 2. With distributor gasket or O-ring in place, hold distributor over mounting pad. 3. Turn rotor to a position just ahead of the No. 1 distributor cap terminal. 4. Install distributor, engaging distributor gear with camshaft drive gear on 6 cylinder engines. On V-8 engines, engage tang of distributor shaft with slot in oil pump drive gear. With distributor fully seated on engine, rotor should be under No. 1 cap terminal. 5. Install distributor hold-down and/or bolt, distributor cap, pickup lead(s) and vacuum line. 6. Adjust ignition timing to specifications found in the Tune Up section. Distributor Shaft & Bushing Wear Test 1. Remove distributor from vehicle and clamp distributor in a vise. Use extreme caution not to damage distributor. 2. Attach a dial indicator to housing so plunger rests against reluctor sleeve. 3. Place a wire loop around reluctor sleeve and hook a spring scale on the other end of the loop. Apply a 1-1/2 lb. pull toward dial indicator. Apply a 1 lb. pull away from dial indicator and read movement on indicator. 4. Movement must not exceed .006 inch. If movement exceeds limit, replace either housing or shaft to bring movement back within tolerance. Distributor Disassembly 1. Remove rotor and vacuum advance unit, if equipped Fig. 14. 2. Remove reluctor by prying up from bottom of reluctor using two screwdrivers with a maximum blade width of 7/16 in. Use care not to damage or distort reluctor teeth. 3. Remove two screws and lockwashers attaching lower plate to distributor housing, then lift out lower plate, upper plate and pickup coil as an assembly. Do not remove distributor cap clamp springs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 2996 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 4. On eight cylinder units, if distributor housing, shaft, reluctor sleeve or governor weights are to be replace, proceed as follows: a. Remove distributor shaft retaining pin and slide retainer off end of shaft. b. If necessary, use a file to clean burrs from around pin hole area on shaft, then remove lower thrust washer. c. Push shaft upward and remove from distributor housing. Distributor Assembly Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > RWD W/ Electronic Spark Control > Page 2997 Fig. 14 Typical disassembled view of Chrysler electronic 8 cylinder distributor (Dual pickup distributor similar) 1. Lubricate and test operation of governor weights. Inspect weight springs for distortion and bearing surfaces and pins for damage. 2. Lubricate upper thrust washer and install onto shaft. Install shaft into housing. 3. On eight cylinder units, install distributor shaft retainer and pin, Fig. 14. 4. On all units, install lower plate, upper plate and pickup coil assembly. 5. Attach vacuum advance unit to pickup plate, then install vacuum advance unit attaching screws and washers. 6. Position reluctor keeper pin into place on reluctor sleeve, then slide reluctor down reluctor sleeve and press firmly into position. Install keeper pin. 7. Lubricate felt pad located in top of reluctor sleeve with one drop of light engine oil, then install rotor. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3002 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3003 Ignition Switch: Electrical Diagrams Fig. 19 Ignition Switch Less Tilt Wheel & Starter Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3004 Fig. 19 Ignition Switch Less Tilt Wheel & Starter Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3005 Fig. 20 Ignition Switch With Tilt Wheel Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 3006 Ignition Switch: Service and Repair Fig. 1 Lock cylinder removal. Less tilt steering wheel MODELS LESS TILT STEERING 1. Disconnect battery ground cable and remove turn signal switch as outlined in this chapter. 2. Remove ignition key lamp assembly attaching screws, then the assembly. 3. Remove snap ring from upper end of steering shaft. 4. Remove bearing housing to lock housing attaching screws, then the bearing housing from the shaft. 5. Remove buzzer switch attaching screws, then the buzzer switch, if equipped. 6. Remove lock lever guide plate attaching screws, then the lock plate. 7. Place lock cylinder in the "Lock" position and remove key. Using a suitable tool, depress spring loaded lock retainer and pull lock cylinder from housing bore. 8. Remove ignition switch attaching screws, then the ignition switch. 9. Reverse procedure to install. Fig. 2 Lock cylinder removal. W/tilt steering wheel MODELS WITH TILT STEERING Fig. 2 Lock cylinder removal. W/tilt steering wheel Ignition Lock, Replace Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Diagrams > Page 3007 The ignition switch and lock assembly are separate units and must be replaced individually. 1. Disconnect battery ground cable and remove turn signal switch as outlined in this chapter. 2. Place lock cylinder in the "Lock" position and remove key. Insert suitable tool into slot next to switch mounting screw boss. 3. Depress spring latch at bottom of slot, then remove lock. 4. To install ignition lock, place lock cylinder in the "Lock" position and remove key. Install lock cylinder assembly into housing, then press inward and move switch actuator rod up and down to align parts. When parts align, the lock cylinder will move inward and a spring loaded retainer will snap into place, locking cylinder into housing. Ignition Switch, Replace The ignition switch is located on the top of the steering column under the instrument panel. To replace it, the steering column should be lowered as follows: 1. Disconnect shift indicator link. 2. Remove nuts securing bracket to dash panel and carefully lower column. 3. Disconnect electrical connector from switch. Ensure switch is in "Accessory" position. 4. Remove switch attaching screws, then the switch. 5. To install ignition switch, place switch slider and lock in the "Accessory" position. 6. Fit actuator rod into switch and assemble to column. 7. Complete assembly in reverse of removal procedure. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Component Locations Detonation (Knock) Sensor: Component Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Component Locations > Page 3012 Engine Mounted Switches & Sensors Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Detonation (Knock) Sensor <--> [Knock Sensor] > Component Information > Locations > Page 3013 Detonation (Knock) Sensor: Description and Operation Fig. 12 Detonation sensor location. V8 engine The detonation sensor, Fig. 12, is used on V8 engines only and is located in the intake manifold. It signals the computer when detonation occurs so that the ignition timing can be retarded. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Control Relay > Component Information > Locations Spark Control Relay: Locations Electronic Ignition System Components On Firewall Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Orifice Spark Advance Control (OSAC) <--> [Vacuum Restrictor] > Component Information > Description and Operation Orifice Spark Advance Control (OSAC): Description and Operation The OSAC system is used on some vehicles to aid in the control of oxides of nitrogen (NOx). The system controls the vacuum to the vacuum advance actuator of the distributor. A tiny orifice is incorporated in the OSAC valve which delays the change in ported vacuum to the distributor by about 17 seconds (27 seconds on some models) when going from idle to part throttle. When going from part throttle to idle, the change in ported vacuum to the distributor will be instantaneous. The valve will only delay the ported vacuum signal when the ambient temperature is about 60° F. or above. Vacuum is obtained by a vacuum tap just above the throttle plates of the carburetor. This type of tap provides no vacuum at idle, but provides manifold vacuum as soon as the throttle plates are opened slightly. Proper operation of this valve depends on air tight fittings and hoses and on freedom from sticking or plugging due to deposits. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Technical Service Bulletins > Customer Interest for Transfer Case Actuator: > 020286 > Apr > 86 > Front Axle - No 4X4 Engagement Transfer Case Actuator: Customer Interest Front Axle - No 4X4 Engagement No. 02-02-86 P-1425 Date April 21, 1986 Index FRONT SUSPENSION Subject Front Axle Disconnect Will Not Engage Models 1985-1986 "W" & "AW" Models With Front Axle Disconnect SYMPTOM/CONDITION No engagement of four wheel drive after shift into "4H" or "4L". DIAGNOSIS Check the actuator at the front axle for vacuum lines being disconnected. If the lines are disconnected, it could be due to mud or snow packing around the vacuum motor and vacuum lines, and causing the vacuum lines to disconnect from the motor. REPAIR PROCEDURE This repair involves the installation of a revised vacuum motor shield. 1. Remove the present vacuum motor shield from the axle. 2. Reinstall vacuum lines and new clamps, PN 6032173, on vacuum motor. 3. Install new vacuum motor shield, PN 04384135. 4. Check vacuum motor for proper operation. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 02-60-05-90 0.3 Hrs. FAILURE CODE: 65 - Leaks Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transfer Case Actuator: > 020286 > Apr > 86 > Front Axle - No 4X4 Engagement Transfer Case Actuator: All Technical Service Bulletins Front Axle - No 4X4 Engagement No. 02-02-86 P-1425 Date April 21, 1986 Index FRONT SUSPENSION Subject Front Axle Disconnect Will Not Engage Models 1985-1986 "W" & "AW" Models With Front Axle Disconnect SYMPTOM/CONDITION No engagement of four wheel drive after shift into "4H" or "4L". DIAGNOSIS Check the actuator at the front axle for vacuum lines being disconnected. If the lines are disconnected, it could be due to mud or snow packing around the vacuum motor and vacuum lines, and causing the vacuum lines to disconnect from the motor. REPAIR PROCEDURE This repair involves the installation of a revised vacuum motor shield. 1. Remove the present vacuum motor shield from the axle. 2. Reinstall vacuum lines and new clamps, PN 6032173, on vacuum motor. 3. Install new vacuum motor shield, PN 04384135. 4. Check vacuum motor for proper operation. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 02-60-05-90 0.3 Hrs. FAILURE CODE: 65 - Leaks Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Testing and Inspection Temperature Warning Indicator - A/T: Testing and Inspection Fig. 3 Recreational vehicle sensor package instrument cluster. 1980 Fig. 4 Recreational vehicle sensor package instrument cluster. 1981-82 The recreational vehicle sensor package consists of a separate instrument cluster, Figs. 3 and 4, which allows the driver to monitor the following conditions: engine oil level, engine coolant level, transmission fluid level and transmission fluid temperature. TROUBLESHOOTING VOLTAGE LIMITER TEST 1. Connect voltmeter between temperature sending unit (locating in fitting in bottom radiator tank) and a suitable ground. Do not disconnect electrical connector from sending unit. 2. Turn ignition switch to On position and observe voltmeter. 3. If voltmeter needle fluctuates, the voltage limiter is operating properly. 4. If voltmeter does not fluctuate, replace voltage limiter. The voltage limiter is located on the sensor panel. To gain access to the limiter, remove panel and unsnap the back cover. TEMPERATURE GAUGE TEST 1. Disconnect electrical connector from temperature sending unit in lower radiator tank. 2. Connect tester No. C-3826 or equivalent between temperature sending unit and a suitable ground. 3. Move tester pointer to ``C'' position, then turn ignition switch On and observe temperature gauge. Temperature gauge should read within 1/8 inch of ``C''. 4. Move tester pointer to ``M'' position. Temperature gauge should now advance to normal range left of 1/2 position on dial. 5. Move tester pointer to ``H'' position. Temperature gauge should now advance to ``H'' position on dial. 6. If temperature gauge responds to tests described in steps 3, 4 and 5, but does not operate when sending unit electrical connector is attached, the sending unit is defective and should be replaced. 7. If temperature gauge does not respond to tests described in steps 3, 4 and 5, check for loose connections, broken wire, open printed circuit or faulty gauge. OIL LEVEL PUSH BUTTON SWITCH 1. Inspect switch for poor solder connections and repair or replace as necessary. 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the switch should be replaced. To replace switch, Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Testing and Inspection > Page 3044 remove circuit board and push switch toward back of sensor housing. PRINTED CIRCUIT BOARD 1. Inspect conductors for cracks or damaged circuits. 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the sensor panel assembly should be replaced. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Indicator Lamp: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3050 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3051 Fig. 14 Four Wheel Drive Indicator Lamp Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Technical Service Bulletins > Customer Interest for Transfer Case Actuator: > 020286 > Apr > 86 > Front Axle - No 4X4 Engagement Transfer Case Actuator: Customer Interest Front Axle - No 4X4 Engagement No. 02-02-86 P-1425 Date April 21, 1986 Index FRONT SUSPENSION Subject Front Axle Disconnect Will Not Engage Models 1985-1986 "W" & "AW" Models With Front Axle Disconnect SYMPTOM/CONDITION No engagement of four wheel drive after shift into "4H" or "4L". DIAGNOSIS Check the actuator at the front axle for vacuum lines being disconnected. If the lines are disconnected, it could be due to mud or snow packing around the vacuum motor and vacuum lines, and causing the vacuum lines to disconnect from the motor. REPAIR PROCEDURE This repair involves the installation of a revised vacuum motor shield. 1. Remove the present vacuum motor shield from the axle. 2. Reinstall vacuum lines and new clamps, PN 6032173, on vacuum motor. 3. Install new vacuum motor shield, PN 04384135. 4. Check vacuum motor for proper operation. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 02-60-05-90 0.3 Hrs. FAILURE CODE: 65 - Leaks Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transfer Case Actuator: > 020286 > Apr > 86 > Front Axle - No 4X4 Engagement Transfer Case Actuator: All Technical Service Bulletins Front Axle - No 4X4 Engagement No. 02-02-86 P-1425 Date April 21, 1986 Index FRONT SUSPENSION Subject Front Axle Disconnect Will Not Engage Models 1985-1986 "W" & "AW" Models With Front Axle Disconnect SYMPTOM/CONDITION No engagement of four wheel drive after shift into "4H" or "4L". DIAGNOSIS Check the actuator at the front axle for vacuum lines being disconnected. If the lines are disconnected, it could be due to mud or snow packing around the vacuum motor and vacuum lines, and causing the vacuum lines to disconnect from the motor. REPAIR PROCEDURE This repair involves the installation of a revised vacuum motor shield. 1. Remove the present vacuum motor shield from the axle. 2. Reinstall vacuum lines and new clamps, PN 6032173, on vacuum motor. 3. Install new vacuum motor shield, PN 04384135. 4. Check vacuum motor for proper operation. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 02-60-05-90 0.3 Hrs. FAILURE CODE: 65 - Leaks Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications Band: Specifications Adjustments Adjustments A-904T A-999 A-727 Kickdown Turns (Front) * 2 1/2 2 1/2 2 1/2 Low-Reverse Turns (Internal) * 4 4 2 * Backed off from 72 in. lbs. ( 8 N.m ) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Adjustments > Front Band Adjustment Band: Adjustments Front Band Adjustment The kickdown band adjusting screw is located on the left side of the transmission case. 1. Loosen lock nut and back off approximately five turns. Test adjusting for free turning in the transmission case. 2. Using wrench, Tool C-3380-A with adapter C-3705, tighten adjusting screw 47 to 50 in. lbs. ( 5 N.m ), if adapter C-3705 is not used, tighten adjusting screws to 72 in, lbs. (8 N.m) which is the true torque. 3. Back off adjusting screw the number of turns listed in "Specification". Hold adjusting screw in this position and tighten lock nut to 35 ft. lbs. (47 N.m). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Adjustments > Front Band Adjustment > Page 3074 Band: Adjustments Rear Band Adjustment 1. Raise vehicle, drain transmission fluid from loosened oil pan and remove oil pan. 2. Loosen adjusting screw lock nut and back off nut approximately five turns. Test adjusting screw for free turning in the lever. 3. Using wrench, Tool C-3380-A, tighten band adjusting screw to 72 in. lbs. (8 N.m). 4. Back off adjusting screw the number of turns listed in "Specifications". Hold adjusting screw in this position and tighten lock nut to 30 ft. lbs. (41 N.m). 5. Reinstall oil pan using a new gasket tighten oil pan bolts to 150 in. lbs. (17 N.m). 6. Fill transmission with DEXRON II Automatic Transmission Fluid. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Automatic Transmission - New Fluid Type Fluid - A/T: Technical Service Bulletins Automatic Transmission - New Fluid Type Models All 1978-1985 Equipped With Automatic Transmission & Lock-Up Torque Converter Subject New Automatic Transmission Fluid Index TRANSMISSION Date June 17, 1985 No. 21-04-85 P-2131 A new automatic transmission fluid Type 7176, (PN 4318077 - quart and 4318079 - 55 gallon) has been released for all vehicles equipped with automatic transmission and lock-up torque converter. Aftermarket fluids can vary in terms of their friction characteristics and this in turn can affect the performance of the lock-up clutch, causing shudder and/or excessive slippage. Use of the new fluid will help to insure that the lock-up clutch will perform satisfactorily after the fluid has been replaced. Type 7176 fluid should be used any time it is necessary to replace the fluid in a lock-up torque converter equipped transmission. If a lock-up shudder condition is encountered, check all linkage adjustments and drain and refill the transmission with Type 7176 fluid prior to attempting any other repairs, especially if the fluid has been changed previously. POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Transaxle/Transmission - Automatic Fluid - A/T: Specifications Transaxle/Transmission - Automatic TYPE.................................................................................................................................................... ......................................................................AF‡, AP CAPACITY, Initial Refill*: All models................ .............................................................................................................................................................. ...........3.8 Liters 4.0 Quarts *With engine at operating temperature, shift transmission through all gears. Check fluid level in NEUTRAL and add fluid as needed ‡1986 and later may use AF only when AP is not available Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Transaxle/Transmission - Automatic > Page 3081 Fluid - A/T: Specifications Initial Refill Capacity TYPE.................................................................................................................................................... ......................................................................AF‡, AP CAPACITY, Initial Refill*: All models................ .............................................................................................................................................................. ...........3.8 Liters 4.0 Quarts *With engine at operating temperature, shift transmission through all gears. Check fluid level in NEUTRAL and add fluid as needed ‡1986 and later may use AF only when AP is not available Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Temperature Warning Indicator - A/T > Component Information > Testing and Inspection Temperature Warning Indicator - A/T: Testing and Inspection Fig. 3 Recreational vehicle sensor package instrument cluster. 1980 Fig. 4 Recreational vehicle sensor package instrument cluster. 1981-82 The recreational vehicle sensor package consists of a separate instrument cluster, Figs. 3 and 4, which allows the driver to monitor the following conditions: engine oil level, engine coolant level, transmission fluid level and transmission fluid temperature. TROUBLESHOOTING VOLTAGE LIMITER TEST 1. Connect voltmeter between temperature sending unit (locating in fitting in bottom radiator tank) and a suitable ground. Do not disconnect electrical connector from sending unit. 2. Turn ignition switch to On position and observe voltmeter. 3. If voltmeter needle fluctuates, the voltage limiter is operating properly. 4. If voltmeter does not fluctuate, replace voltage limiter. The voltage limiter is located on the sensor panel. To gain access to the limiter, remove panel and unsnap the back cover. TEMPERATURE GAUGE TEST 1. Disconnect electrical connector from temperature sending unit in lower radiator tank. 2. Connect tester No. C-3826 or equivalent between temperature sending unit and a suitable ground. 3. Move tester pointer to ``C'' position, then turn ignition switch On and observe temperature gauge. Temperature gauge should read within 1/8 inch of ``C''. 4. Move tester pointer to ``M'' position. Temperature gauge should now advance to normal range left of 1/2 position on dial. 5. Move tester pointer to ``H'' position. Temperature gauge should now advance to ``H'' position on dial. 6. If temperature gauge responds to tests described in steps 3, 4 and 5, but does not operate when sending unit electrical connector is attached, the sending unit is defective and should be replaced. 7. If temperature gauge does not respond to tests described in steps 3, 4 and 5, check for loose connections, broken wire, open printed circuit or faulty gauge. OIL LEVEL PUSH BUTTON SWITCH 1. Inspect switch for poor solder connections and repair or replace as necessary. 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the switch should be replaced. To replace switch, Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Temperature Warning Indicator - A/T > Component Information > Testing and Inspection > Page 3086 remove circuit board and push switch toward back of sensor housing. PRINTED CIRCUIT BOARD 1. Inspect conductors for cracks or damaged circuits. 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the sensor panel assembly should be replaced. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Temperature Warning Indicator - A/T > Component Information > Testing and Inspection Temperature Warning Indicator - A/T: Testing and Inspection Fig. 3 Recreational vehicle sensor package instrument cluster. 1980 Fig. 4 Recreational vehicle sensor package instrument cluster. 1981-82 The recreational vehicle sensor package consists of a separate instrument cluster, Figs. 3 and 4, which allows the driver to monitor the following conditions: engine oil level, engine coolant level, transmission fluid level and transmission fluid temperature. TROUBLESHOOTING VOLTAGE LIMITER TEST 1. Connect voltmeter between temperature sending unit (locating in fitting in bottom radiator tank) and a suitable ground. Do not disconnect electrical connector from sending unit. 2. Turn ignition switch to On position and observe voltmeter. 3. If voltmeter needle fluctuates, the voltage limiter is operating properly. 4. If voltmeter does not fluctuate, replace voltage limiter. The voltage limiter is located on the sensor panel. To gain access to the limiter, remove panel and unsnap the back cover. TEMPERATURE GAUGE TEST 1. Disconnect electrical connector from temperature sending unit in lower radiator tank. 2. Connect tester No. C-3826 or equivalent between temperature sending unit and a suitable ground. 3. Move tester pointer to ``C'' position, then turn ignition switch On and observe temperature gauge. Temperature gauge should read within 1/8 inch of ``C''. 4. Move tester pointer to ``M'' position. Temperature gauge should now advance to normal range left of 1/2 position on dial. 5. Move tester pointer to ``H'' position. Temperature gauge should now advance to ``H'' position on dial. 6. If temperature gauge responds to tests described in steps 3, 4 and 5, but does not operate when sending unit electrical connector is attached, the sending unit is defective and should be replaced. 7. If temperature gauge does not respond to tests described in steps 3, 4 and 5, check for loose connections, broken wire, open printed circuit or faulty gauge. OIL LEVEL PUSH BUTTON SWITCH 1. Inspect switch for poor solder connections and repair or replace as necessary. 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the switch should be replaced. To replace switch, Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Temperature Warning Indicator - A/T > Component Information > Testing and Inspection > Page 3090 remove circuit board and push switch toward back of sensor housing. PRINTED CIRCUIT BOARD 1. Inspect conductors for cracks or damaged circuits. 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the sensor panel assembly should be replaced. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Torque Converter - Replacement Conditions Torque Converter: Technical Service Bulletins Torque Converter - Replacement Conditions Models All 1978-1985 Domestic Cars & Trucks Equipped With Automatic Transmission/ Transaxle Subject Torque Converter Replacement Index TRANSMISSION Date May 28, 1985 No. 21-11-85 P-1796-C The drainless torque converter, introduced in February, 1977, prevents the ability to completely flush the converter. To eliminate the possibility of a repeat transmission failure, it is necessary that the torque converter be replaced if any of the following conditions exist when the transmission is being replaced or repaired: ^ There is a heavy accumulation of dirt or contamination in the bottom of the oil pan. ^ The transmission oil is burnt or black. ^ Small particles can be seen suspended in the oil. ^ Excessive torque converter hub damage has occurred. ^ The problem is directly related to the torque converter. In addition to the above conditions, the transmission cooler lines should be flushed thoroughly to clean the transmission's hydraulic system. (Refer to the appropriate service manual for the recommended procedure.) POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T Cooler - Flushing Procedure Transmission Cooler: Technical Service Bulletins A/T Cooler - Flushing Procedure Models All Domestic Vehicles with Automatic Transmission Coolers Subject Transmission Cooler Flushing Procedure Index TRANSMISSION Date June 5, 1989 No. 21-10-89 REVISION A P-2170 (C21-12-9) BODY CODE LEGEND ALL DOMESTIC CHRYSLER/PLYMOUTH & DODGE VEHICLES THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN # 21-10-89, DATE 04/24/89, WHICH SHOULD BE REMOVED FROM YOUR FILE. THIS REVISION CORRECTS AN ERROR IN THE A-6Q4 ILLUSTRATION. SYMPTOM/CONDITION Repeated automatic transmission failures. REPAIR PROCEDURE The purpose of this bulletin is to emphasize the importance of properly flushing the transmission oil cooler following any repair which requires the removal or replacement of any automatic transmission or transaxle. Clogged or restricted transmission oil coolers can be a cause of recurring transmission failures. Restriction of cooler flow can cause overheating of the transmission fluid and reduce important lubrication to internal rotating parts. Although several styles of transmission coolers are in use, including various oil-to-air designs and those internal to the radiator tank, all have small internal passages which can trap debris, such as loose lock-up clutch friction material and become clogged. It is absolutely necessary, in any case of transmission failure, to thoroughly flush the cooler, following the procedure outlined below and then check the flow to ensure that all possible debris has been removed. When reverse flushing an automatic transmission cooler the following procedure should be used: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T Cooler - Flushing Procedure > Page 3099 FIGURE 1 - A604 TRANSAXLE FIGURE 2 - A413/A670 TRANSAXLE FIGURE 3 - REAR WHEEL DRIVE TRANSMISSION Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T Cooler - Flushing Procedure > Page 3100 1. Identify the To Cooler and From Cooler lines from the accompanying figures. 2. Disconnect the cooler lines at the transmission. 3. Using a hand suction gun filled with mineral spirits, reverse flush the cooler by forcing mineral spirits into the From Cooler line of the cooler and catching the exiting spirits from the To Cooler line. Observe for the presence of debris in the exiting fluid. Continue until fluid exiting is clear and free from debris. NOTE: IF AT ALL POSSIBLE, THE COOLER SHOULD BE REMOVED FROM THE VEHICLE AND THE CLEANING DONE USING A PRESSURE TYPE PARTS CLEANER. 4. Using compressed air in intermittent spurts, blow any remaining mineral spirits from the cooler, again in the reverse direction. 5. To remove any remaining mineral spirits from the cooler, one (1) quart of ATF should be pumped through the cooler prior to reconnecting the hoses to the transmission. 6. If at any stage of the cleaning process, the cooler does not freely pass fluid, the cooler must be replaced. After the new or repaired transmission has been installed and filled to the proper level with ATF, the flow should be checked using the following procedure: 1. Disconnect the From Cooler line at the transmission and place a collecting container under the disconnected line. 2. Run the engine at curb idle speed, with the shift selector in neutral. 3. If the fluid flow is intermittent or it takes more than 20 seconds to collect one quart of ATF, the cooler should be replaced. CAUTION: WITH THE FLUID SET AT THE PROPER LEVEL, FLUID COLLECTION SHOULD NOT EXCEED (1) QUART OR INTERNAL DAMAGE TO THE TRANSMISSION MAY OCCUR. 4. If flow is found to be within acceptable limits, reconnect the cooler line and fill transmission to the proper level, using the approved type of ATF. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 090286 > Feb > 86 > Engine/Transmission -Droning/Moaning Noise Transmission Mount: Customer Interest Engine/Transmission -Droning/Moaning Noise No. 09-02-86 P-672 Date February 24, 1986 Index ENGINE Subject "Moan or Drone" at 1600-2100 Engine RPM Models 1984-1986 Rear Wheel Drive Domestic Passenger Cars 1981-1986 "D" Series Trucks With Automatic Transmission SYMPTOM/CONDITION Passenger Car & Truck These vehicles may exhibit a moaning or droning noise which occurs at approximately 1800 engine rpm (for V8 engines), or 2100 rpm (for 6- cylinder engines), in any gear. This noise is sometimes misdiagnosed as an "exhaust system drone", it is not always caused by the exhaust system. Addition of a damper weight to the rear of the transmission extension can help reduce this noise. Only the A904/A999 transmission extension has provision for mounting this weight; it cannot be used with the A727 transmission. Truck Only A new rear engine mount insulator, which also reduces the moaning noise. It can be used on all trucks, including those with the A727 transmission. Trucks with the A904/A999 transmission can use the weight, and the rear engine mount. PARTS REQUIRED For all subject trucks: 1 Engine Rear Support Insulator Assembly PN 4412962 (A904, 999 and 727 transmission) 2 Screw/Washer Assembly PN 6029770 For trucks or passenger cars with A904/A999 transmission order: 1 Damper Weight Assembly PN 4412542 1 Plate PN 3681614 2 Washers PN 6032046 2 Screws - PN 6032047 REPAIR PROCEDURE It will be necessary to install a damper weight and/or rear transmission support to correct this condition. Truck 1. To replace the engine rear support insulator assembly: a. With the vehicle on a hoist, position a transmission jack and raise the rear of the transmission and engine slightly. b. Remove the rear mount through-bolt. c. Remove the insulator assembly and spacers from the bottom of the transmission extension housing. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Mount: > 090286 > Feb > 86 > Engine/Transmission -Droning/Moaning Noise > Page 3109 d. Install the new insulator assembly on the transmission extension, with the spacers between the screws and the insulator bracket. Use new screws and torque them to 50 foot pounds. e. Reinstall the rear mount through-bolt and torque to 50 foot pounds. f. Remove the transmission jack. 2. To install the damper weight assembly: a. Position the damper weight assembly and plate on the mounting pad at the extreme rear end of the transmission extension. The plate must be in between the weight and the transmission extension. b. Install the screws and washers as shown in Figure 1, and torque the screws to 150 inch pounds. Passenger Car 1. Remove existing damper weight from transmission extension. 2. Install new damper weight, making sure that spacers and washers are installed as shown in Figure 1. Torque screws to 150 inch pounds. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 21-95-40-91 0.2 Hrs. FAILURE CODE: OX - Wrong Part Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 090286 > Feb > 86 > Engine/Transmission -Droning/Moaning Noise Transmission Mount: All Technical Service Bulletins Engine/Transmission -Droning/Moaning Noise No. 09-02-86 P-672 Date February 24, 1986 Index ENGINE Subject "Moan or Drone" at 1600-2100 Engine RPM Models 1984-1986 Rear Wheel Drive Domestic Passenger Cars 1981-1986 "D" Series Trucks With Automatic Transmission SYMPTOM/CONDITION Passenger Car & Truck These vehicles may exhibit a moaning or droning noise which occurs at approximately 1800 engine rpm (for V8 engines), or 2100 rpm (for 6- cylinder engines), in any gear. This noise is sometimes misdiagnosed as an "exhaust system drone", it is not always caused by the exhaust system. Addition of a damper weight to the rear of the transmission extension can help reduce this noise. Only the A904/A999 transmission extension has provision for mounting this weight; it cannot be used with the A727 transmission. Truck Only A new rear engine mount insulator, which also reduces the moaning noise. It can be used on all trucks, including those with the A727 transmission. Trucks with the A904/A999 transmission can use the weight, and the rear engine mount. PARTS REQUIRED For all subject trucks: 1 Engine Rear Support Insulator Assembly PN 4412962 (A904, 999 and 727 transmission) 2 Screw/Washer Assembly PN 6029770 For trucks or passenger cars with A904/A999 transmission order: 1 Damper Weight Assembly PN 4412542 1 Plate PN 3681614 2 Washers PN 6032046 2 Screws - PN 6032047 REPAIR PROCEDURE It will be necessary to install a damper weight and/or rear transmission support to correct this condition. Truck 1. To replace the engine rear support insulator assembly: a. With the vehicle on a hoist, position a transmission jack and raise the rear of the transmission and engine slightly. b. Remove the rear mount through-bolt. c. Remove the insulator assembly and spacers from the bottom of the transmission extension housing. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Mount: > 090286 > Feb > 86 > Engine/Transmission -Droning/Moaning Noise > Page 3115 d. Install the new insulator assembly on the transmission extension, with the spacers between the screws and the insulator bracket. Use new screws and torque them to 50 foot pounds. e. Reinstall the rear mount through-bolt and torque to 50 foot pounds. f. Remove the transmission jack. 2. To install the damper weight assembly: a. Position the damper weight assembly and plate on the mounting pad at the extreme rear end of the transmission extension. The plate must be in between the weight and the transmission extension. b. Install the screws and washers as shown in Figure 1, and torque the screws to 150 inch pounds. Passenger Car 1. Remove existing damper weight from transmission extension. 2. Install new damper weight, making sure that spacers and washers are installed as shown in Figure 1. Torque screws to 150 inch pounds. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 21-95-40-91 0.2 Hrs. FAILURE CODE: OX - Wrong Part Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations Transmission Pressure Test Port: Locations Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Adjustments Clutch Pedal Assembly: Adjustments Adjust fork rod by turning self-locking adjusting nut to provide free movement at end of fork. Adjustment should be 3/32 inch. This movement will provide approximately 1 to 1-1/2 inches of freeplay at pedal. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations Clutch Switch: Locations On Clutch Pedal Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Customer Interest for Fluid - Differential: > 211587 > Aug > 87 > Transfer Case High Effort Shifting From 2-H to 4-H Fluid - Differential: Customer Interest Transfer Case - High Effort Shifting From 2-H to 4-H Models 1985-1987 "W" & "AW" Trucks With NP208 Transfer Case & "N" Body 4 x 4 With NP207 Transfer Case Subject High Shift Effort When Shifting From 2-High to 4-High Index TRANSMISSION Date August 17, 1987 No.. 21-15-87 (C10-21) P-2869 SYMPTOM/CONDITION High shift effort or total block out while shifting into 4-High (four-wheel drive transfer case). Condition occurs during cold weather operation while shifting the transfer case into 4-High from the 2-High mode. DIAGNOSIS With vehicle cold (below +30~F), shift transfer case from 2-High into 4-High with the vehicle stationary. It may be necessary to move vehicle slightly forward or rearward to engage front axle. If the transfer case does not shift with the vehicle stationary, check external shift linkage for proper adjustment (see appropriate service manual for transfer case shift linkage adjustment procedure). With vehicle still cold, attempt to shift from 2-High to 4-High at approximately 25 mph. While shifting, apply a constant force to the transfer case shift lever, not a quick pull. This will allow the synchronizer time to get the front propshaft up to speed. With cold front axle lubricant, the vehicle may require high effort for an extended time, or will not shift. Warm front axle lubricant by operating vehicle in 4-High mode for approximately 10 miles. Shift transfer case from 2-High to 4-High several times. Allow time between shifts to insure synchronizer is out of the 4-High mode before shifting. If vehicle exhibits high shifting effort in cold weather operation (below +30~F), but has reasonable effort and consistency after vehicle is warm, perform the front axle lubricant fill procedure as outlined later in this bulletin. If vehicle requires high shifting effort and shifts inconsistently after the front axle lubricant is warm, the following transfer case parts might require replacement, in addition to the front axle lubricant change. PARTS REQUIRED Transfer Case - NP208 ("W" and "AW" Truck) 1 Synchronizer Assembly PN 4329516 1 Drive Sprocket Assembly PN 4329527 Transfer Case - NP207 (N5 Dakota 4 x 4) 1 Synchronizer Assembly PN 4446457 1 Drive Sprocket Assembly PN 4446453 Front Axle Mopar High Performance Synthetic PN 4467707 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Customer Interest for Fluid - Differential: > 211587 > Aug > 87 > Transfer Case High Effort Shifting From 2-H to 4-H > Page 3138 Axle Lube (1 quart can) REPAIR PROCEDURES This procedure involves replacing the synchronizer assembly and axle lube. Transfer Case See appropriate service manual for replacement procedures. Front Axle 1. Using a suction pump, remove as much of the axle lubricant as possible. NOTE: IT IS NOT NECESSARY TO REMOVE THE DIFFERENTIAL COVER. 2. Refill the axle with Mopar High Performance Synthetic Axle Lube, PN 4467707, as specified below. "W" and "AW" Truck: Fill to within 1/4" of the bottom of the fill plug hole (approximately 84 ounces). N5 Dakota 4 x 4: Fill to 1/2" below the bottom of the fill plug hole (approximately 40 ounces). NOTE: OVERFILL CAN RESULT IN LUBRICANT "FOAMING" AND/OR UNIT OVERHEATING. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Refer to Labor Operation Time Schedule for operation and time Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - Differential: > 211587 > Aug > 87 > Transfer Case - High Effort Shifting From 2-H to 4-H Fluid - Differential: All Technical Service Bulletins Transfer Case - High Effort Shifting From 2-H to 4-H Models 1985-1987 "W" & "AW" Trucks With NP208 Transfer Case & "N" Body 4 x 4 With NP207 Transfer Case Subject High Shift Effort When Shifting From 2-High to 4-High Index TRANSMISSION Date August 17, 1987 No.. 21-15-87 (C10-21) P-2869 SYMPTOM/CONDITION High shift effort or total block out while shifting into 4-High (four-wheel drive transfer case). Condition occurs during cold weather operation while shifting the transfer case into 4-High from the 2-High mode. DIAGNOSIS With vehicle cold (below +30~F), shift transfer case from 2-High into 4-High with the vehicle stationary. It may be necessary to move vehicle slightly forward or rearward to engage front axle. If the transfer case does not shift with the vehicle stationary, check external shift linkage for proper adjustment (see appropriate service manual for transfer case shift linkage adjustment procedure). With vehicle still cold, attempt to shift from 2-High to 4-High at approximately 25 mph. While shifting, apply a constant force to the transfer case shift lever, not a quick pull. This will allow the synchronizer time to get the front propshaft up to speed. With cold front axle lubricant, the vehicle may require high effort for an extended time, or will not shift. Warm front axle lubricant by operating vehicle in 4-High mode for approximately 10 miles. Shift transfer case from 2-High to 4-High several times. Allow time between shifts to insure synchronizer is out of the 4-High mode before shifting. If vehicle exhibits high shifting effort in cold weather operation (below +30~F), but has reasonable effort and consistency after vehicle is warm, perform the front axle lubricant fill procedure as outlined later in this bulletin. If vehicle requires high shifting effort and shifts inconsistently after the front axle lubricant is warm, the following transfer case parts might require replacement, in addition to the front axle lubricant change. PARTS REQUIRED Transfer Case - NP208 ("W" and "AW" Truck) 1 Synchronizer Assembly PN 4329516 1 Drive Sprocket Assembly PN 4329527 Transfer Case - NP207 (N5 Dakota 4 x 4) 1 Synchronizer Assembly PN 4446457 1 Drive Sprocket Assembly PN 4446453 Front Axle Mopar High Performance Synthetic PN 4467707 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - Differential: > 211587 > Aug > 87 > Transfer Case - High Effort Shifting From 2-H to 4-H > Page 3144 Axle Lube (1 quart can) REPAIR PROCEDURES This procedure involves replacing the synchronizer assembly and axle lube. Transfer Case See appropriate service manual for replacement procedures. Front Axle 1. Using a suction pump, remove as much of the axle lubricant as possible. NOTE: IT IS NOT NECESSARY TO REMOVE THE DIFFERENTIAL COVER. 2. Refill the axle with Mopar High Performance Synthetic Axle Lube, PN 4467707, as specified below. "W" and "AW" Truck: Fill to within 1/4" of the bottom of the fill plug hole (approximately 84 ounces). N5 Dakota 4 x 4: Fill to 1/2" below the bottom of the fill plug hole (approximately 40 ounces). NOTE: OVERFILL CAN RESULT IN LUBRICANT "FOAMING" AND/OR UNIT OVERHEATING. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Refer to Labor Operation Time Schedule for operation and time Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Differentials Fluid - Differential: Specifications Differentials Above 90° (32°C), 140, 80W-140, 85W-140; above -10°F (-23°C), 90, 80W-90, 80W-140; 85W-140; below -10°F (-23°C), 75W, 80W, 75W-90, 80W-140 REAR: Standard................................................................................................................................... ..........................................................................GL-5 Anti-Spin, Limited-Slip, Powr-Loc, Sure-Grip, Trac-Loc....................................................................... ......................................................................GL-5* FRONT: 4 x 4....................................................................................................................................... .........................................................................GL-5 CAPACITY, Refill: Front: 4-wheel drive Dakota. .............................................................................................................................................................. .................................1.2 Liters 2.6 Pints Spicer 60F axle..................................................................................................................................... ..............................................3.1 Liters 6.5 Pints Others................................................................................................................................................... ..............................................2.7 Liters 5.6 Pints Rear 7 1/4" ring gear with 2 1/2" dia. axle housing adjacent to differential.........................................................................................1.2 Liters 2.5 Pints Spicer 60, 60 HD.................................................................................................................................. ..............................................2.8 Liters 6.0 Pints Spicer 70.............................................................................................................................................. ...............................................3.3 Liters 7.0 Pints Others................................................................................................................................................... ..............................................2.1 Liters 4.5 Pints ANTI-SPIN, LIMITED-SLIP, POWR-LOC, SURE-GRIP OR TRAC-LOC IDENTIFICATION Lift both rear wheels off ground, turn one wheel & other will rotate in same direction Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Differentials > Page 3147 Fluid - Differential: Specifications Differential Above 90° (32°C), 140, 80W-140, 85W-140; above -10°F (-23°C), 90, 80W-90, 80W-140; 85W-140; below -10°F (-23°C), 75W, 80W, 75W-90, 80W-140 REAR: Standard................................................................................................................................... ..........................................................................GL-5 Anti-Spin, Limited-Slip, Powr-Loc, Sure-Grip, Trac-Loc....................................................................... ......................................................................GL-5* FRONT: 4 x 4....................................................................................................................................... .........................................................................GL-5 CAPACITY, Refill: Front: 4-wheel drive Dakota. .............................................................................................................................................................. .................................1.2 Liters 2.6 Pints Spicer 60F axle..................................................................................................................................... ..............................................3.1 Liters 6.5 Pints Others................................................................................................................................................... ..............................................2.7 Liters 5.6 Pints Rear 7 1/4" ring gear with 2 1/2" dia. axle housing adjacent to differential.........................................................................................1.2 Liters 2.5 Pints Spicer 60, 60 HD.................................................................................................................................. ..............................................2.8 Liters 6.0 Pints Spicer 70.............................................................................................................................................. ...............................................3.3 Liters 7.0 Pints Others................................................................................................................................................... ..............................................2.1 Liters 4.5 Pints ANTI-SPIN, LIMITED-SLIP, POWR-LOC, SURE-GRIP OR TRAC-LOC IDENTIFICATION Lift both rear wheels off ground, turn one wheel & other will rotate in same direction Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair Axle Bearing: Service and Repair Fig. 4 Removing differential pinion shaft lock pin Fig. 5 Removing C-lock washers Fig. 6 Removing axle shaft bearing and seal. Exc. 9-1/4 inch HD axle Fig. 7 Removing axle shaft & bearing seal. 1984-87 9-1/4 inch HD axle 8-3/8 & 9-1/4 INCH 1. Raise and support vehicle and remove brake drum. 2. Clean area around housing cover, then loosen housing cover and allow lubricant to drain. Remove cover. 3. Turn differential case until pinion shaft lock screw is accessible and remove lock screw and pinion shaft. 4. Push axle shaft inward and remove C-washer locks from axle shaft, then pull axle shaft from housing being careful not to damage axle shaft bearing. Inspect axle shaft bearing surfaces for signs of spalling or pitting. If any of these conditions exist, both shaft and bearing should be replaced. Normal bearing contact on shaft should be a dull gray and may appear lightly dented. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Page 3152 5. Remove axle shaft bearing and seal from axle housing using tools C-4167 and C-637 on all models except 1984-87 9-1/4 inch HD axle, or tool C-4828 on 1984-87 9-1/4 inch HD axle. If bearing shows no sign of excessive wear or damage, it can be reused along with a new seal. Never reuse an axle shaft seal. Remove any burrs that may be present in housing bearing shoulder, as bearing could become cocked during installation. Fig. 8 Installing axle shaft oil seal 6. Using suitable tools, install bearing, making sure it does not become cocked. Drive bearing until it bottoms against shoulder. Do not use seal to position or bottom bearing as this will damage seal. 7. Using tool C-4130 or equivalent, install axle shaft bearing seal until outer flange of tool bottoms against housing flange face. This will position seal to the proper depth. 8. Reverse disassembly procedure to reassemble axle. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Halfshaft U-Joint Type Axle Shaft Axle Shaft: Service and Repair Halfshaft U-Joint Type Axle Shaft Front Axle - Dana 44FBJ and 44-8FD 1985-87 Right Axle Shaft, Removal 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove caliper retainer and anti-rattle spring assemblies. 4. Remove caliper from brake disc. Hang caliper aside. Do not allow caliper to hang from brake lines. 5. Remove braking disc. 6. Remove six nuts attaching splash shield and spindle to knuckle assembly. 7. Remove brake caliper adapter from knuckle. 8. Carefully remove axle shaft assembly from vehicle. Remove seal and stone shield. Right Axle Shaft, Installation 1. Install lip seal on axle shaft stone shield with lip toward axle shaft spline. 2. Carefully insert axle shaft into the housing. 3. Install spindle and splash shield. Install, then torque nuts to 25-30 ft-lbs. 4. Install braking disc, outer bearing, nut, washer and locknut onto spindle. 5. Install spring retainer, spring, drive gear and drive gear snap ring. 6. Apply RTV sealant or equivalent to seating edge of grease cap, then install the cap. 7. Install brake adapter and torque mounting bolts to 85 ft-lbs. 8. Position inboard brake shoe on adapter with shoe flanges in adapter keyways. Slowly slide caliper assembly into position in adapter and over braking disc. Align caliper on machined ways of adapter. 9. Install anti-rattle springs and retaining clips. Torque to 180 inch lbs. 10. Install tire and wheel assembly. Left Axle Shaft, Removal 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Remove caliper retainer and anti-rattle spring assemblies. 4. Remove caliper from brake disc. 5. Hang caliper aside. Do not allow brake caliper to hang from brake lines. 6. Remove inboard brake shoe. 7. Remove brake disc, splash shield and spindle. 8. Disconnect vacuum lines and electrical connector from disconnect housing assembly switch. 9. Remove disconnect housing assembly from vehicle as previously described. 10. Remove intermediate axle shaft assembly. Carefully slide shaft through axle shaft seal to avoid damaging the seal assembly. 11. Using tool D-330 or equivalent, remove needle bearing from intermediate axle shaft. 12. Remove shift collar from axle housing. 13. Loosen, then remove differential cover attaching screws. Remove cover and drain lubricant. 14. Push inner axle shaft toward center of vehicle and remove C-lock form shaft groove recess. 15. Using tools D-354-4 and D-354-1 or equivalents, remove inner axle shaft bearing. 16. Remove outer axle shaft bearing and seal from housing bore. Left Axle Shaft, Installation 1. Using tools D-354-4, D-354-2 and C-367 or equivalents, install inner axle shaft bearing. 2. Using a suitable tool, install inner axle shaft. Install C-lock into axle shaft groove recess. 3. Install shift collar on splined end of inner axle shaft. 4. Install axle shaft bearing and seal. 5. Install needle bearing into intermediate axle shaft. 6. Install intermediate axle shaft through seal. 7. Install disconnect housing assembly and gasket as previously described. 8. Install disconnect housing assembly shield and bolts. Torque bolts to 10 ft-lbs. 9. Connect vacuum lines and electrical connectors to switch assembly. 10. Install splash shield and spindle. Torque nuts to 25-30 ft-lbs. 11. Install brake disc, outer bearing, nut, washer and locknut on spindle assembly. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Halfshaft U-Joint Type Axle Shaft > Page 3158 12. Install spring retainer, spring, drive gear and drive gear snap ring. 13. Apply RTV sealant to seating edge of grease cap, then install the cap. 14. Position inboard brake shoe on adapter with shoe flanges in adapter keyways. Slowly slide caliper assembly into position in adapter and over brake disc. 15. Install anti-rattle springs and retaining clips. Torque to 180 inch lbs. 16. Apply a 1/16 inch bead of suitable sealant along bolt circle of cover. 17. Allow sealant to cure and install on axle. Torque attaching bolts to 420 inch lbs. 18. Remove fill plug and fill axle with suitable lubricant. 19. Install tire and wheel assembly. Removal Fig. 19 Removing snap ring. 60 Front Axle Fig. 20 Removing hub lock nut. 60 Front Axle Fig. 21 Removing or replacing axle shaft. 60 Front Axle Fig. 22 Removing or replacing upper socket pin. 60 Front Axle Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Halfshaft U-Joint Type Axle Shaft > Page 3159 Fig. 23 Universal joint, spindle and bushing assembly. (Typical) 1. Block brake pedal in "Up" position. 2. Raise and support vehicle. 3. Remove wheel. 4. Remove brake caliper from adapter and, using a piece of wire, suspend caliper. Do not hang caliper by brake hose. The inner brake pad will remain on adapter. 5. Remove hub cap and snap ring. 6. Remove flange nuts and lock washers. 7. Remove drive flange and discard gasket, or remove locking hub, if equipped. 8. Straighten tang on lock ring, then remove outer locknut, lock ring, inner locknut and outer-bearing. Slide hub and rotor assembly from spindle. 9. Remove inner brake pad from adapter. 10. Remove nuts and washers securing brake splash shield, brake adapter and spindle to steering knuckle. 11. Remove spindle from knuckle. Slide inner and outer axle shaft with bronze spacer, seal and slinger from axle. 12. Remove cotter key and nut from tie rod. Disconnect tie rod from steering knuckle. 13. On left side only, remove cotter key and nut from drag link. Disconnect drag link from steering knuckle arm. Also, remove nuts and upper knuckle cap. Discard gasket. Remove spring and upper socket sleeve. 14. Remove capscrews from lower knuckle cap and free cap from knuckle and housing. 15. To remove knuckle from housing, swing outward at bottom, then lift up and off upper socket pin. 16. Using a suitable tool, loosen and remove upper socket pin, then the seal. 17. Press lower ball socket from axle housing with suitable tools. 18. Disassemble shaft. Assembly & Installation Fig. 21 Removing or replacing axle shaft. 60 Front Axle Fig. 22 Removing or replacing upper socket pin. 60 Front Axle Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Halfshaft U-Joint Type Axle Shaft > Page 3160 Fig. 23 Universal joint, spindle and bushing assembly. (Typical) Fig. 24 Correct alignment of upper socket pin to steering knuckle. 60 Front Axle 1. Lubricate lower ball socket assembly with suitable grease. 2. With suitable tools, press seal and lower bearing cup into axle housing. Then, press lower bearing and seal into axle housing. 3. Using a suitable tool and torque wrench, install and torque upper socket pin to 500-600 ft. lbs. Install seal over socket pin. 4. Place steering knuckle over socket pin. Fill lower socket cavity with suitable grease. Work lower knuckle cap into place on knuckle and housing. Install capscrews and torque to 70-90 ft-lbs. 5. Lubricate upper socket pin with suitable grease. Align upper socket sleeve in keyway of steering knuckle and slide into position. 6. Install new gasket over upper steering knuckle studs. Place spring over sleeve. Install cap on left side steering knuckle arm. Install nuts and torque to 70-90 ft-lbs. 7. On left side only, attach drag link to steering knuckle arm and install and torque nut to 60 ft-lbs. 8. Connect tie rod to steering knuckle and install and torque nut to 45 ft-lbs, Install cotter key. 9. Assemble shaft. 10. Slide axle shaft into position. Place bronze spacer on axle shaft with chamfer facing toward universal joint. 11. Install spindle, brake adapter and splash shield. Install and torque nuts to 50-70 ft-lbs. 12. Place inner brake pad on adapter. Fig. 19 Removing snap ring. 60 Front Axle 13. Install hub and rotor assembly onto spindle. Install outer bearing and inner locknut. Using tool DD-1241-JD and tool C-3952, torque locknut to 50 ft-lbs, to seat bearings. Then, back off locknut and retorque to 30-40 ft-lbs, while rotating hub and rotor. Back off nut 135 to 150 degrees. Assemble lock ring and outer locknut. Torque locknut to 65 ft-lbs, minimum. Bend one tang of lock ring over inner locknut and another tang over outer locknut. Bearing endplay should be 0.001-0.010 inch. 14. Install new gasket on hub, then the drive flange, lock washers and nuts. Torque nuts to 30-40 ft-lbs. Install snap ring and hub cap, or locking hub, if equipped. 15. Position caliper on adapter and torque Allen screw to 12-18 ft-lbs. 16. Install wheel and lower vehicle. 17. Remove block from brake pedal. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Halfshaft U-Joint Type Axle Shaft > Page 3161 Axle Shaft: Service and Repair Conventional Fixed/Floating Axle Shaft Axle Shaft Removal and Installation SPICER TYPE 1. Remove axle shaft flange nuts and lock washers. 2. Remove tapered dowels and axle shaft assembly by tapping axle shaft sharply in center of flange with a suitable hammer. 3. Reverse procedure to install. Axle Shafts & Bearings Replace Fig. 4 Removing differential pinion shaft lock pin Fig. 5 Removing C-lock washers Fig. 6 Removing axle shaft bearing and seal. Exc. 9-1/4 inch HD axle Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Halfshaft U-Joint Type Axle Shaft > Page 3162 Fig. 7 Removing axle shaft & bearing seal. 1984-87 9-1/4 inch HD axle 8-3/8 & 9-1/4 INCH 1. Raise and support vehicle and remove brake drum. 2. Clean area around housing cover, then loosen housing cover and allow lubricant to drain. Remove cover. 3. Turn differential case until pinion shaft lock screw is accessible and remove lock screw and pinion shaft. 4. Push axle shaft inward and remove C-washer locks from axle shaft, then pull axle shaft from housing being careful not to damage axle shaft bearing. Inspect axle shaft bearing surfaces for signs of spalling or pitting. If any of these conditions exist, both shaft and bearing should be replaced. Normal bearing contact on shaft should be a dull gray and may appear lightly dented. 5. Remove axle shaft bearing and seal from axle housing using tools C-4167 and C-637 on all models except 1984-87 9-1/4 inch HD axle, or tool C-4828 on 1984-87 9-1/4 inch HD axle. If bearing shows no sign of excessive wear or damage, it can be reused along with a new seal. Never reuse an axle shaft seal. Remove any burrs that may be present in housing bearing shoulder, as bearing could become cocked during installation. Fig. 8 Installing axle shaft oil seal 6. Using suitable tools, install bearing, making sure it does not become cocked. Drive bearing until it bottoms against shoulder. Do not use seal to position or bottom bearing as this will damage seal. 7. Using tool C-4130 or equivalent, install axle shaft bearing seal until outer flange of tool bottoms against housing flange face. This will position seal to the proper depth. 8. Reverse disassembly procedure to reassemble axle. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments EXC. MOTOR HOME & 4 WHEEL DRIVE 1. Torque adjusting nut to 360-480 inch lbs. for Vans, Wagons and Front Sections or 90 inch lbs. for Ramcharger, Trail Duster and Conventional Cabs while rotating wheel. 2. Stop wheel from rotating, then back off adjusting nut to completely release bearing preload. 3. Tighten adjusting nut finger tight, then install locknut and cotter key. End play should be 0.0001 to 0.003 inch. 4. Clean grease cap, coat inside with suitable wheel bearing grease and install cap. Do not fill cap with grease. MOTOR HOME 1. Rotate wheel and tighten adjusting nut until a slight binding is felt. 2. Back off adjusting nut so that the nearest slot indexes with the cotter pin hole in the spindle. Never back off adjusting nut less than half the distance from one slot to the next slot. 3. Install cotter pin to locknut and ensure that wheel rotates freely. 4 WHEEL DRIVE SPICER 44FBJ & 44-8FD Axle 1. Raise and support vehicle. 2. Remove locking hub assembly, then the wheel bearing locknut and washer. 3. Torque adjusting nut to 50 ft. lbs., using tool No. C-4170 or equivalent, to seat the bearing. 4. Loosen adjusting nut and retorque to 30-40 ft. lbs. while rotating hub, then back off adjusting nut 135°-150°. 5. Install retaining washer and bearing locknut. Torque locknut to 50 ft. lbs. Endplay should be 0.001 to 0.010 inch. SPICER 60 Axle 1. Raise and support vehicle. 2. Remove hub cap, then the snap ring using suitable pliers. 3. Remove flange nuts and lock washers, then the drive flange or locking hub if equipped. 4. Straighten tang on lock ring, then using tool No. DD-1241-JD or equivalent, remove outer locknut and lock ring. 5. Torque locknut to 50 ft. lbs. to seat the bearing, loosen locknut and retorque to 30-40 ft. lbs. Back off locknut 135°-150°. 6. Install lock ring and outer locknut. Torque locknut to 65 ft. lbs. 7. Bend tangs of long ring over both locknuts. Endplay should be 0.001 to 0.010 inch. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 160185 > Dec > 85 > Driveline Clunk or Snap Slip Yoke: Customer Interest Driveline - Clunk or Snap Models 1980-1986 Ramcharger 4-Wheel Drive W-150 Truck Subject Driveline "Clunk" or "Snap" Index PROP SHAFT & U JOINTS Date December 23,1985 No. 16-01-85 SYMPTOM/CONDITION Customer concern for a "snap" or "clunk". ^ After medium-heavy brake application to a stop is completed. ^ When accelerating from a stop. ^ At the 1-2 upshift. DIAGNOSIS Description of Condition Drive line "snap" is a single snap or clunk noise sometimes heard when braking to a forward stop or accelerating from a stop. It is ordinarily heard just as a stop is completed, when the vehicle transitions from the nose-down braking attitude to the level-stationary attitude. It may also be heard just as motion begins on acceleration or at the 1-2 upshift. Forward direction braking causes the rear axle pinion noise to pitch downward from brake torque reaction. The vehicle also assumes an overall nose-down attitude. The combination of these motions results in maximum rearward excursion of the prop shaft in the slip yoke. At the end of the stopping maneuver, the prop shaft would ordinarily slide smoothly back into the slip yoke. The characteristic "snap" occurs when the prop shaft momentarily binds in the rearward position, then abruptly "snaps" forward to the neutral position. PARTS REQUIRED 1 Boot Package PN 4137901 REPAIR PROCEDURE This repair consists of installing a boot package on the slip yoke. 1. Raise vehicle. 2. Remove rear driveshaft and slip yoke assembly. 3. Remove slip yoke from driveshaft. Inspect the splines on the driveshaft and in the slip yoke for wear. Replace if excessive wear is observed. 4. Remove and discard the slip yoke snap-on rubber seal. 5. Thoroughly clean all old grease out of the slip yoke and driveshaft splines with a suitable solvent. 6. After cleaning the slip yoke in solvent, clean the cup plug vent hole area with Mopar Brake and Carburetor Cleaner, PN 4318037. Seal the vent hole with an epoxy (2 part) cement (Duro Depend II, PN MITB-1, or equivalent). Allow cure time as stated in the instructions. 7. Remove the slip yoke grease fitting and install the 1/4"-28 pipe plug supplied in the kit. 8. Apply and spread not more than half the supplied lubricant to the slip yoke splines and driveshaft (Excessive grease may fill the boot and the slip Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 160185 > Dec > 85 > Driveline Clunk or Snap > Page 3175 yoke and result in propshaft imbalance or knocking of the slip yoke plug.) 9. Install the boot on the driveshaft and the clamp, using Miller Tool #C-4653 as follows: a. Wrap binding strap around boot twice, plus 63 mm (2-1/2 inches). b. Pass the strap through the buckle and fold it back about 29 mm (1-1/8 inches) on the inside of the buckle. c. Put the strip around the boot with the eye of the buckle toward you. Wrap the strip around the boot once and pass it through the buckle, then wrap it around a second time also passing it through the buckle. d. Fold the strip back slightly to prevent it from slipping backwards. e. Open the tool all the way and place strip in narrow slot approximately 13 mm (1/2 inch) from buckle. f. Hold the binding strip with the left hand and push the tool forward and slightly upward. Then fit the hook of the tool into the eye of the buckle. g. Tighten the strip by closing the tool handles. Then rotate the tool (handles) downward while slowly releasing the pressure on the tool handles. Allow the tool (handles) to open progressively. Then open the tool entirely and remove them sideways. h. If the strap is not tight enough, re-engage the tool a second or even a third time, always about 13 mm (112 inch) from the buckle. When tightening always be careful to see that the strap slides in a straight line and without resistance in the buckle, that is without making a fold. An effective grip will be obtained only by following the above instructions. 10. Install the slip yoke on the driveshaft. (Make sure universal joints are placed properly.) 11. Install boot and second clamp on the slip yoke with the splined stub extended approximately 1.5" from the fully collapsed position, and the boot vented at this position before installing the clamp, using the same procedure as in Step 9. 12. Install driveshaft in truck. Road test vehicle to assure that "clunk" or "snap" is corrected. Advise the customer that it is no longer necessary to lubricate the slip yoke. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 16-30-10-91 0.8 Hrs. FAILURE CODE: 07 - Binds, Sticks or Seized Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 160185 > Dec > 85 > Driveline - Clunk or Snap Slip Yoke: All Technical Service Bulletins Driveline - Clunk or Snap Models 1980-1986 Ramcharger 4-Wheel Drive W-150 Truck Subject Driveline "Clunk" or "Snap" Index PROP SHAFT & U JOINTS Date December 23,1985 No. 16-01-85 SYMPTOM/CONDITION Customer concern for a "snap" or "clunk". ^ After medium-heavy brake application to a stop is completed. ^ When accelerating from a stop. ^ At the 1-2 upshift. DIAGNOSIS Description of Condition Drive line "snap" is a single snap or clunk noise sometimes heard when braking to a forward stop or accelerating from a stop. It is ordinarily heard just as a stop is completed, when the vehicle transitions from the nose-down braking attitude to the level-stationary attitude. It may also be heard just as motion begins on acceleration or at the 1-2 upshift. Forward direction braking causes the rear axle pinion noise to pitch downward from brake torque reaction. The vehicle also assumes an overall nose-down attitude. The combination of these motions results in maximum rearward excursion of the prop shaft in the slip yoke. At the end of the stopping maneuver, the prop shaft would ordinarily slide smoothly back into the slip yoke. The characteristic "snap" occurs when the prop shaft momentarily binds in the rearward position, then abruptly "snaps" forward to the neutral position. PARTS REQUIRED 1 Boot Package PN 4137901 REPAIR PROCEDURE This repair consists of installing a boot package on the slip yoke. 1. Raise vehicle. 2. Remove rear driveshaft and slip yoke assembly. 3. Remove slip yoke from driveshaft. Inspect the splines on the driveshaft and in the slip yoke for wear. Replace if excessive wear is observed. 4. Remove and discard the slip yoke snap-on rubber seal. 5. Thoroughly clean all old grease out of the slip yoke and driveshaft splines with a suitable solvent. 6. After cleaning the slip yoke in solvent, clean the cup plug vent hole area with Mopar Brake and Carburetor Cleaner, PN 4318037. Seal the vent hole with an epoxy (2 part) cement (Duro Depend II, PN MITB-1, or equivalent). Allow cure time as stated in the instructions. 7. Remove the slip yoke grease fitting and install the 1/4"-28 pipe plug supplied in the kit. 8. Apply and spread not more than half the supplied lubricant to the slip yoke splines and driveshaft (Excessive grease may fill the boot and the slip Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 160185 > Dec > 85 > Driveline - Clunk or Snap > Page 3181 yoke and result in propshaft imbalance or knocking of the slip yoke plug.) 9. Install the boot on the driveshaft and the clamp, using Miller Tool #C-4653 as follows: a. Wrap binding strap around boot twice, plus 63 mm (2-1/2 inches). b. Pass the strap through the buckle and fold it back about 29 mm (1-1/8 inches) on the inside of the buckle. c. Put the strip around the boot with the eye of the buckle toward you. Wrap the strip around the boot once and pass it through the buckle, then wrap it around a second time also passing it through the buckle. d. Fold the strip back slightly to prevent it from slipping backwards. e. Open the tool all the way and place strip in narrow slot approximately 13 mm (1/2 inch) from buckle. f. Hold the binding strip with the left hand and push the tool forward and slightly upward. Then fit the hook of the tool into the eye of the buckle. g. Tighten the strip by closing the tool handles. Then rotate the tool (handles) downward while slowly releasing the pressure on the tool handles. Allow the tool (handles) to open progressively. Then open the tool entirely and remove them sideways. h. If the strap is not tight enough, re-engage the tool a second or even a third time, always about 13 mm (112 inch) from the buckle. When tightening always be careful to see that the strap slides in a straight line and without resistance in the buckle, that is without making a fold. An effective grip will be obtained only by following the above instructions. 10. Install the slip yoke on the driveshaft. (Make sure universal joints are placed properly.) 11. Install boot and second clamp on the slip yoke with the splined stub extended approximately 1.5" from the fully collapsed position, and the boot vented at this position before installing the clamp, using the same procedure as in Step 9. 12. Install driveshaft in truck. Road test vehicle to assure that "clunk" or "snap" is corrected. Advise the customer that it is no longer necessary to lubricate the slip yoke. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 16-30-10-91 0.8 Hrs. FAILURE CODE: 07 - Binds, Sticks or Seized Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Service Notes Universal Joint: Service and Repair Service Notes Fig. 1 Production type universal joints which use nylon injection rings in place of snap rings Before disassembling any universal joint, examine the assembly carefully and note the position of the grease fitting (if used). Also, be sure to mark the yokes with relation to the propeller shaft so they may be reassembled in the same relative position. Failure to observe these precautions may produce rough vehicle operation which results in rapid wear and failure of parts, and place an unbalanced load on transmission, engine and rear axle. When universal joints are disassembled for lubrication or inspection, and the old parts are to be reinstalled, special care must be exercised to avoid damage to universal joint spider or cross and bearing cups. Some driveshafts use an injected nylon retainer on the universal joint bearings. When service is necessary, pressing the bearings out will sheer the nylon retainer. Replacement with the conventional steel snap ring type is then necessary. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Service Notes > Page 3186 Universal Joint: Service and Repair Single Cardan Joint Fig. 3 Cross & roller type universal joints Fig. 4 Cross & roller type universal joints & propeller shaft Illustrations show typical examples of universal joints of this type. They all operate on the same principle and similar service and replacement Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Service Notes > Page 3187 procedures may be applied to all. Fig. 5 Removing bearings from yoke using a small socket as a driver & large socket as a receiver WITHOUT UNIVERSAL JOINT REPLACEMENT TOOL DISASSEMBLY 1. Remove snap rings (or retainer plates) that retain bearings in yoke and drive shaft. 2. Place U-joint in a vise. 3. Select a wrench socket with an outside diameter slightly smaller than the U-joint bearings. Select another wrench socket with an inside diameter slightly larger than the U-joint bearings. 4. Place the sockets at opposite bearings in the yoke so that the smaller socket becomes a bearing pusher and the larger socket becomes a bearing receiver when the vise jaws come together. Close vise jaws until both bearings are free of yoke and remove bearings from the cross or spider. 5. If bearings will not come all the way out, close vise until bearing in receiver socket protrudes from yoke as much as possible without using excessive force. Then remove from vise and place that portion of bearing which protrudes from yoke between vise jaws. Tighten vise to hold bearing and drive yoke off with a soft hammer. 6. To remove opposite bearing from yoke, replace in vise with pusher socket on exposed cross journal with receiver socket over bearing cup. Then tighten vise jaws to press bearing back through yoke into receiving socket. 7. Remove yoke from drive shaft and again place protruding portion of bearing between vise jaws. Then tighten vise to hold bearing while driving yoke off bearing with soft hammer. 8. Turn spider or cross 1/4 turn and use the same procedure to press bearings out of drive shaft. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Service Notes > Page 3188 Fig. 6 Installing bearings into driveshaft yoke ASSEMBLY 1. If old parts are to be reassembled, pack bearing cups with universal joint grease. Do not fill cups completely or use excessive amounts as over lubrication may damage seals during reassembly. Use new seals. 2. If new parts are being installed, check new bearings for adequate grease before assembling. 3. With the pusher (smaller) socket, press one bearing part way into drive shaft. Position spider into the partially installed bearing. Place second bearing into drive shaft. Fasten drive shaft in vise so that bearings are in contact with faces of vise jaws. Some spiders are provided with locating lugs which must face toward drive shaft when installed. 4. Press bearings all the way into position and install snap rings or retainer plates. 5. Install bearings in yoke in same manner. When installation is completed, check U-joint for binding or roughness. If free movement is impeded, correct the condition before installation in vehicle. Fig. 7 Removing bearing caps using tool & adapter Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Service Notes > Page 3189 Fig. 8 Removing bearing cap by holding cap in vise & striking center yoke with hammer WITH UNIVERSAL JOINT REPLACEMENT TOOL DISASSEMBLY 1. Place driveshaft in a vise using care to avoid damaging it. 2. Remove bearing retaining snap rings. Some universal joints use injected nylon retainers in place of snap rings. During servicing, the snap rings supplied with the replacement universal joint assembly must be used. 3. Position tool on shaft and press bearing out of yoke. If bearing cannot be pressed all the way out, remove it using vise grips or channel lock pliers or position driveshaft as shown and strike center yoke with hammer. Mark yoke and shaft to make sure they will be reassembled in their same relative positions. 4. Reposition tool so that it presses on the spider in order to press other bearing from opposite side of flange. 5. If used, remove flange from spider. ASSEMBLY 1. Start new bearing into yoke, then position spider into yoke and press bearing until it is 1/4 inch below surface. 2. Remove tool and install a new snap ring. 3. Start new bearing in opposite side of yoke, then install tool and press on bearing until opposite bearing contacts snap ring. 4. Remove tool and install remaining snap ring. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Service Notes > Page 3190 Universal Joint: Service and Repair Constant Velocity Type Fig. 9 Constant velocity (CV) universal joint This type of universal joint, consists of two conventional cross and roller joints connected with a special link yoke. Because the two joint angles are the same, even though the usual universal joint fluctuation is present within the unit, the acceleration of the front joint (within the yoke) is always neutralized by the deceleration of the rear joint (within the yoke) and vice versa. The end result is the front and rear propeller shafts always turn at a constant velocity. Fig. 10 Bearing cap removal sequence Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Service Notes > Page 3191 Fig. 11 Alignment punch marks Fig. 12 Cross press being used in place of socket DISASSEMBLY CONSTANT VELOCITY JOINT To disassemble the constant velocity joint, the bearings should be removed in sequence shown. This method requires the least amount of work. 1. Mark all yokes before disassembly as shown, so that they can be reassembled in their original relationship to maintain driveshaft balance. The following procedure can be performed in a vise and a cross press tool, can be used in place of the socket used to drive the bearings. 2. Support the driveshaft horizontally in line with the base plate of a press. Place rear end of coupling yoke over a 1-1/8 inch socket to accept the bearing. Place a socket slightly smaller than the bearing on the opposite side of the spider. Fig. 13 Using spacer to completely drive out bearing Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Service Notes > Page 3192 Fig. 14 Solid ball & replaceable balls. Notch identifies driveshaft w/replaceable ball Fig. 15 Ball & seat exploded view 3. Press bearing cup out of coupling yoke ear. If bearing cup is not completely removed, insert spacer C-4365-4 or equivalent, and complete removal of bearing cup. 4. Rotate driveshaft 180° and shear the opposite retaining ring, and press the bearing cup out of the coupling yoke as described previously, using spacer C-4365-4 or equivalent. 5. Disengage cross trunnions, still attached to flange yoke, from coupling yoke. Pull flange yoke and cross from centering ball on ball support tube yoke. The ball socket is part of the flange yoke. The ball on some joints is not replaceable. The joints with a replaceable ball can be recognized as shown. Do not attempt to remove solid ball, as removal tool may be damaged. 6. Pry seal from ball cavity, then remove washers, spring and shoes. Fig. 16 Removing centering ball BALL SOCKET 1. To remove ball, separate universal joint between coupling yoke and flange yoke by pressing out trunnion bearing in coupling yoke. Pull flange yoke and cross with ball socket from centering ball as a unit. 2. Clean and inspect ball seat insert bushing for wear. If worn, replace flange yoke and cross assembly. 3. Pry seal from ball cavity, then remove washers, spring and ball seats. 4. Clean and inspect centering ball surface, seal, ball seats, spring and washer. If parts are worn or broken, replace with a service kit. 5. Remove centering ball as shown, using components of tool C-4365 or equivalent. Install components as shown, and draw ball off ball stud. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Service Notes > Page 3193 Fig. 11 Alignment punch marks Fig. 17 Inserting cross into yoke Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Service Notes > Page 3194 Fig. 18 Aligning bearing cups & journals ASSEMBLY BALL SOCKET & CONSTANT VELOCITY JOINT During assembly, make sure that marks made during disassembly, are aligned to maintain balance. 1. To install centering ball onto stud, use tool C-4365 or equivalent, and drive ball until it can be seen that ball has seated firmly against shoulder at base of stud. 2. To install cross assembly, install one bearing cup part way into one side of yoke and turn this yoke to the bottom. Insert cross into yoke so that the trunnion seats into bearing. Install opposite bearing cup part way. Make sure that both cross journals are started straight into both bearing cups. Fig. 19 Relieving binding condition at point A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Service Notes > Page 3195 Fig. 20 Relieving binding condition at point B Fig. 21 Relieving binding condition at point C 3. Press bearing cups, while moving cross to ensure free movement of trunnions in bearing. If any binding is felt, stop pressing and check needle bearings to make sure that needle bearings have not been trapped under the ends of the cross journals. 4. As soon as one of the retaining ring grooves clears the inside of yoke, stop pressing and install retaining ring. 5. Continue to press until opposite retaining ring can be snapped into place. If difficulty is encountered, strike the yoke firmly in locations shown to spring the yoke ears slightly. 6. Lubricate center ball and socket, and assemble other half universal joint, if disassembled. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Service Notes > Page 3196 Universal Joint: Service and Repair Lubrication Fig. 22 Lubrication fitting adapter Fig. 23 Lubrication fitting adapter & fitting location Fig. 24 Lubrication fitting locations Lubrication of the constant velocity joints should not be overlooked during the regular service intervals recommended by the manufacturer. During lubrication, use only the type of lubricant recommended by the manufacturer. This lubricant is usually lithium type chassis grease. Lubrication fitting adapters and locations of the lubrication fittings are shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Flywheel to Crankshaft Bolts 55 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Testing and Inspection Temperature Warning Indicator - A/T: Testing and Inspection Fig. 3 Recreational vehicle sensor package instrument cluster. 1980 Fig. 4 Recreational vehicle sensor package instrument cluster. 1981-82 The recreational vehicle sensor package consists of a separate instrument cluster, Figs. 3 and 4, which allows the driver to monitor the following conditions: engine oil level, engine coolant level, transmission fluid level and transmission fluid temperature. TROUBLESHOOTING VOLTAGE LIMITER TEST 1. Connect voltmeter between temperature sending unit (locating in fitting in bottom radiator tank) and a suitable ground. Do not disconnect electrical connector from sending unit. 2. Turn ignition switch to On position and observe voltmeter. 3. If voltmeter needle fluctuates, the voltage limiter is operating properly. 4. If voltmeter does not fluctuate, replace voltage limiter. The voltage limiter is located on the sensor panel. To gain access to the limiter, remove panel and unsnap the back cover. TEMPERATURE GAUGE TEST 1. Disconnect electrical connector from temperature sending unit in lower radiator tank. 2. Connect tester No. C-3826 or equivalent between temperature sending unit and a suitable ground. 3. Move tester pointer to ``C'' position, then turn ignition switch On and observe temperature gauge. Temperature gauge should read within 1/8 inch of ``C''. 4. Move tester pointer to ``M'' position. Temperature gauge should now advance to normal range left of 1/2 position on dial. 5. Move tester pointer to ``H'' position. Temperature gauge should now advance to ``H'' position on dial. 6. If temperature gauge responds to tests described in steps 3, 4 and 5, but does not operate when sending unit electrical connector is attached, the sending unit is defective and should be replaced. 7. If temperature gauge does not respond to tests described in steps 3, 4 and 5, check for loose connections, broken wire, open printed circuit or faulty gauge. OIL LEVEL PUSH BUTTON SWITCH 1. Inspect switch for poor solder connections and repair or replace as necessary. 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the switch should be replaced. To replace switch, Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Testing and Inspection > Page 3205 remove circuit board and push switch toward back of sensor housing. PRINTED CIRCUIT BOARD 1. Inspect conductors for cracks or damaged circuits. 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the sensor panel assembly should be replaced. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Indicator Lamp: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3211 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3212 Fig. 14 Four Wheel Drive Indicator Lamp Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications Fluid - M/T: Specifications A833 OD............................................................................................................................................... .......................................................................AF, AP 75W, 75W-80, 80W-90, 85W-90, 90 GL-5may be used NP435........................................................... .................................................................................................................................GL-5, SF/CC, SF/CD, SG SF/CC, SF/CD, SG: Above 32°F (0°C), 50; below 32°F (0°C), 30 GL-5: Above 90°F (32°C), 140; above -10°F (-23°C), 90; below -10°F (-23°C), 80W NP2500 ......................................... .............................................................................................................................................10W-30 SF/CC, SF/CD, SG CAPACITY, Refill: NP435..................................................................................... ...............................................................................................................3.3 Liters 7.0 Pints NP2500................................................................................................................................................. .................................................1.9 Liters 4.0 Pints A833 OD............................................................................................................................................... ................................................3.5 Liters 7.5 Pints Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Component Information > Adjustments Shift Linkage: Adjustments Fig. 1 Gearshift linkage adjustment. Four-speed overdrive FOUR SPEED OVERDRIVE 1. Install gear shift lever aligning tool to hold levers in neutral crossover position. 2. With all rods removed from transmission shift levers, place levers in neutral detent position. 3. Adjust threaded shift rod levers so they enter transmission levers freely without any rearward or forward movement. Start with 1-2 shift rod. It may be necessary to pull clip at shifter end to rotate this rod. 4. Install washers and clips, then remove aligning tool and check linkage operation. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Technical Service Bulletins > Customer Interest for Transfer Case Actuator: > 020286 > Apr > 86 > Front Axle - No 4X4 Engagement Transfer Case Actuator: Customer Interest Front Axle - No 4X4 Engagement No. 02-02-86 P-1425 Date April 21, 1986 Index FRONT SUSPENSION Subject Front Axle Disconnect Will Not Engage Models 1985-1986 "W" & "AW" Models With Front Axle Disconnect SYMPTOM/CONDITION No engagement of four wheel drive after shift into "4H" or "4L". DIAGNOSIS Check the actuator at the front axle for vacuum lines being disconnected. If the lines are disconnected, it could be due to mud or snow packing around the vacuum motor and vacuum lines, and causing the vacuum lines to disconnect from the motor. REPAIR PROCEDURE This repair involves the installation of a revised vacuum motor shield. 1. Remove the present vacuum motor shield from the axle. 2. Reinstall vacuum lines and new clamps, PN 6032173, on vacuum motor. 3. Install new vacuum motor shield, PN 04384135. 4. Check vacuum motor for proper operation. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 02-60-05-90 0.3 Hrs. FAILURE CODE: 65 - Leaks Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transfer Case Actuator: > 020286 > Apr > 86 > Front Axle - No 4X4 Engagement Transfer Case Actuator: All Technical Service Bulletins Front Axle - No 4X4 Engagement No. 02-02-86 P-1425 Date April 21, 1986 Index FRONT SUSPENSION Subject Front Axle Disconnect Will Not Engage Models 1985-1986 "W" & "AW" Models With Front Axle Disconnect SYMPTOM/CONDITION No engagement of four wheel drive after shift into "4H" or "4L". DIAGNOSIS Check the actuator at the front axle for vacuum lines being disconnected. If the lines are disconnected, it could be due to mud or snow packing around the vacuum motor and vacuum lines, and causing the vacuum lines to disconnect from the motor. REPAIR PROCEDURE This repair involves the installation of a revised vacuum motor shield. 1. Remove the present vacuum motor shield from the axle. 2. Reinstall vacuum lines and new clamps, PN 6032173, on vacuum motor. 3. Install new vacuum motor shield, PN 04384135. 4. Check vacuum motor for proper operation. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 02-60-05-90 0.3 Hrs. FAILURE CODE: 65 - Leaks Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Drive Sprocket, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Drive Sprocket: > 211587 > Aug > 87 > Transfer Case High Effort Shifting From 2-H to 4-H Drive Sprocket: Customer Interest Transfer Case - High Effort Shifting From 2-H to 4-H Models 1985-1987 "W" & "AW" Trucks With NP208 Transfer Case & "N" Body 4 x 4 With NP207 Transfer Case Subject High Shift Effort When Shifting From 2-High to 4-High Index TRANSMISSION Date August 17, 1987 No.. 21-15-87 (C10-21) P-2869 SYMPTOM/CONDITION High shift effort or total block out while shifting into 4-High (four-wheel drive transfer case). Condition occurs during cold weather operation while shifting the transfer case into 4-High from the 2-High mode. DIAGNOSIS With vehicle cold (below +30~F), shift transfer case from 2-High into 4-High with the vehicle stationary. It may be necessary to move vehicle slightly forward or rearward to engage front axle. If the transfer case does not shift with the vehicle stationary, check external shift linkage for proper adjustment (see appropriate service manual for transfer case shift linkage adjustment procedure). With vehicle still cold, attempt to shift from 2-High to 4-High at approximately 25 mph. While shifting, apply a constant force to the transfer case shift lever, not a quick pull. This will allow the synchronizer time to get the front propshaft up to speed. With cold front axle lubricant, the vehicle may require high effort for an extended time, or will not shift. Warm front axle lubricant by operating vehicle in 4-High mode for approximately 10 miles. Shift transfer case from 2-High to 4-High several times. Allow time between shifts to insure synchronizer is out of the 4-High mode before shifting. If vehicle exhibits high shifting effort in cold weather operation (below +30~F), but has reasonable effort and consistency after vehicle is warm, perform the front axle lubricant fill procedure as outlined later in this bulletin. If vehicle requires high shifting effort and shifts inconsistently after the front axle lubricant is warm, the following transfer case parts might require replacement, in addition to the front axle lubricant change. PARTS REQUIRED Transfer Case - NP208 ("W" and "AW" Truck) 1 Synchronizer Assembly PN 4329516 1 Drive Sprocket Assembly PN 4329527 Transfer Case - NP207 (N5 Dakota 4 x 4) 1 Synchronizer Assembly PN 4446457 1 Drive Sprocket Assembly PN 4446453 Front Axle Mopar High Performance Synthetic PN 4467707 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Drive Sprocket, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Drive Sprocket: > 211587 > Aug > 87 > Transfer Case High Effort Shifting From 2-H to 4-H > Page 3243 Axle Lube (1 quart can) REPAIR PROCEDURES This procedure involves replacing the synchronizer assembly and axle lube. Transfer Case See appropriate service manual for replacement procedures. Front Axle 1. Using a suction pump, remove as much of the axle lubricant as possible. NOTE: IT IS NOT NECESSARY TO REMOVE THE DIFFERENTIAL COVER. 2. Refill the axle with Mopar High Performance Synthetic Axle Lube, PN 4467707, as specified below. "W" and "AW" Truck: Fill to within 1/4" of the bottom of the fill plug hole (approximately 84 ounces). N5 Dakota 4 x 4: Fill to 1/2" below the bottom of the fill plug hole (approximately 40 ounces). NOTE: OVERFILL CAN RESULT IN LUBRICANT "FOAMING" AND/OR UNIT OVERHEATING. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Refer to Labor Operation Time Schedule for operation and time Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Drive Sprocket, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Sprocket: > 211587 > Aug > 87 > Transfer Case - High Effort Shifting From 2-H to 4-H Drive Sprocket: All Technical Service Bulletins Transfer Case - High Effort Shifting From 2-H to 4-H Models 1985-1987 "W" & "AW" Trucks With NP208 Transfer Case & "N" Body 4 x 4 With NP207 Transfer Case Subject High Shift Effort When Shifting From 2-High to 4-High Index TRANSMISSION Date August 17, 1987 No.. 21-15-87 (C10-21) P-2869 SYMPTOM/CONDITION High shift effort or total block out while shifting into 4-High (four-wheel drive transfer case). Condition occurs during cold weather operation while shifting the transfer case into 4-High from the 2-High mode. DIAGNOSIS With vehicle cold (below +30~F), shift transfer case from 2-High into 4-High with the vehicle stationary. It may be necessary to move vehicle slightly forward or rearward to engage front axle. If the transfer case does not shift with the vehicle stationary, check external shift linkage for proper adjustment (see appropriate service manual for transfer case shift linkage adjustment procedure). With vehicle still cold, attempt to shift from 2-High to 4-High at approximately 25 mph. While shifting, apply a constant force to the transfer case shift lever, not a quick pull. This will allow the synchronizer time to get the front propshaft up to speed. With cold front axle lubricant, the vehicle may require high effort for an extended time, or will not shift. Warm front axle lubricant by operating vehicle in 4-High mode for approximately 10 miles. Shift transfer case from 2-High to 4-High several times. Allow time between shifts to insure synchronizer is out of the 4-High mode before shifting. If vehicle exhibits high shifting effort in cold weather operation (below +30~F), but has reasonable effort and consistency after vehicle is warm, perform the front axle lubricant fill procedure as outlined later in this bulletin. If vehicle requires high shifting effort and shifts inconsistently after the front axle lubricant is warm, the following transfer case parts might require replacement, in addition to the front axle lubricant change. PARTS REQUIRED Transfer Case - NP208 ("W" and "AW" Truck) 1 Synchronizer Assembly PN 4329516 1 Drive Sprocket Assembly PN 4329527 Transfer Case - NP207 (N5 Dakota 4 x 4) 1 Synchronizer Assembly PN 4446457 1 Drive Sprocket Assembly PN 4446453 Front Axle Mopar High Performance Synthetic PN 4467707 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Drive Sprocket, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Sprocket: > 211587 > Aug > 87 > Transfer Case - High Effort Shifting From 2-H to 4-H > Page 3249 Axle Lube (1 quart can) REPAIR PROCEDURES This procedure involves replacing the synchronizer assembly and axle lube. Transfer Case See appropriate service manual for replacement procedures. Front Axle 1. Using a suction pump, remove as much of the axle lubricant as possible. NOTE: IT IS NOT NECESSARY TO REMOVE THE DIFFERENTIAL COVER. 2. Refill the axle with Mopar High Performance Synthetic Axle Lube, PN 4467707, as specified below. "W" and "AW" Truck: Fill to within 1/4" of the bottom of the fill plug hole (approximately 84 ounces). N5 Dakota 4 x 4: Fill to 1/2" below the bottom of the fill plug hole (approximately 40 ounces). NOTE: OVERFILL CAN RESULT IN LUBRICANT "FOAMING" AND/OR UNIT OVERHEATING. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Refer to Labor Operation Time Schedule for operation and time Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications Fluid - Transfer Case: Specifications NP205................................................................................................................................................... .........................................GL-5, SF/CC, SF/CD, SG SF/CC, SF/CD, SG:Above 32°F (0°C), 50; below 32°F (0°C), 30 GL-5: Above 90°F (32°C), 140; above -10°F (-23°C), 90; below -10°F (-23°C, 80W NP207, NP208.................................................... ..........................................................................................................................................................A F, AP CAPACITY, Refill: NP205, NP207.............................................................................................. ........................................................................................2.1 Liters 4.5 Pints NP208................................................................................................................................................... ................................................2.8 Liters 6.0 Pints Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Indicator Lamp: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3257 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3258 Fig. 14 Four Wheel Drive Indicator Lamp Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear, Transfer Case > Synchronizer Hub, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Synchronizer Hub: > 211587 > Aug > 87 > Transfer Case - High Effort Shifting From 2-H to 4-H Synchronizer Hub: Customer Interest Transfer Case - High Effort Shifting From 2-H to 4-H Models 1985-1987 "W" & "AW" Trucks With NP208 Transfer Case & "N" Body 4 x 4 With NP207 Transfer Case Subject High Shift Effort When Shifting From 2-High to 4-High Index TRANSMISSION Date August 17, 1987 No.. 21-15-87 (C10-21) P-2869 SYMPTOM/CONDITION High shift effort or total block out while shifting into 4-High (four-wheel drive transfer case). Condition occurs during cold weather operation while shifting the transfer case into 4-High from the 2-High mode. DIAGNOSIS With vehicle cold (below +30~F), shift transfer case from 2-High into 4-High with the vehicle stationary. It may be necessary to move vehicle slightly forward or rearward to engage front axle. If the transfer case does not shift with the vehicle stationary, check external shift linkage for proper adjustment (see appropriate service manual for transfer case shift linkage adjustment procedure). With vehicle still cold, attempt to shift from 2-High to 4-High at approximately 25 mph. While shifting, apply a constant force to the transfer case shift lever, not a quick pull. This will allow the synchronizer time to get the front propshaft up to speed. With cold front axle lubricant, the vehicle may require high effort for an extended time, or will not shift. Warm front axle lubricant by operating vehicle in 4-High mode for approximately 10 miles. Shift transfer case from 2-High to 4-High several times. Allow time between shifts to insure synchronizer is out of the 4-High mode before shifting. If vehicle exhibits high shifting effort in cold weather operation (below +30~F), but has reasonable effort and consistency after vehicle is warm, perform the front axle lubricant fill procedure as outlined later in this bulletin. If vehicle requires high shifting effort and shifts inconsistently after the front axle lubricant is warm, the following transfer case parts might require replacement, in addition to the front axle lubricant change. PARTS REQUIRED Transfer Case - NP208 ("W" and "AW" Truck) 1 Synchronizer Assembly PN 4329516 1 Drive Sprocket Assembly PN 4329527 Transfer Case - NP207 (N5 Dakota 4 x 4) 1 Synchronizer Assembly PN 4446457 1 Drive Sprocket Assembly PN 4446453 Front Axle Mopar High Performance Synthetic PN 4467707 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear, Transfer Case > Synchronizer Hub, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Synchronizer Hub: > 211587 > Aug > 87 > Transfer Case - High Effort Shifting From 2-H to 4-H > Page 3268 Axle Lube (1 quart can) REPAIR PROCEDURES This procedure involves replacing the synchronizer assembly and axle lube. Transfer Case See appropriate service manual for replacement procedures. Front Axle 1. Using a suction pump, remove as much of the axle lubricant as possible. NOTE: IT IS NOT NECESSARY TO REMOVE THE DIFFERENTIAL COVER. 2. Refill the axle with Mopar High Performance Synthetic Axle Lube, PN 4467707, as specified below. "W" and "AW" Truck: Fill to within 1/4" of the bottom of the fill plug hole (approximately 84 ounces). N5 Dakota 4 x 4: Fill to 1/2" below the bottom of the fill plug hole (approximately 40 ounces). NOTE: OVERFILL CAN RESULT IN LUBRICANT "FOAMING" AND/OR UNIT OVERHEATING. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Refer to Labor Operation Time Schedule for operation and time Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear, Transfer Case > Synchronizer Hub, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Synchronizer Hub: > 211587 > Aug > 87 > Transfer Case - High Effort Shifting From 2-H to 4-H Synchronizer Hub: All Technical Service Bulletins Transfer Case - High Effort Shifting From 2-H to 4-H Models 1985-1987 "W" & "AW" Trucks With NP208 Transfer Case & "N" Body 4 x 4 With NP207 Transfer Case Subject High Shift Effort When Shifting From 2-High to 4-High Index TRANSMISSION Date August 17, 1987 No.. 21-15-87 (C10-21) P-2869 SYMPTOM/CONDITION High shift effort or total block out while shifting into 4-High (four-wheel drive transfer case). Condition occurs during cold weather operation while shifting the transfer case into 4-High from the 2-High mode. DIAGNOSIS With vehicle cold (below +30~F), shift transfer case from 2-High into 4-High with the vehicle stationary. It may be necessary to move vehicle slightly forward or rearward to engage front axle. If the transfer case does not shift with the vehicle stationary, check external shift linkage for proper adjustment (see appropriate service manual for transfer case shift linkage adjustment procedure). With vehicle still cold, attempt to shift from 2-High to 4-High at approximately 25 mph. While shifting, apply a constant force to the transfer case shift lever, not a quick pull. This will allow the synchronizer time to get the front propshaft up to speed. With cold front axle lubricant, the vehicle may require high effort for an extended time, or will not shift. Warm front axle lubricant by operating vehicle in 4-High mode for approximately 10 miles. Shift transfer case from 2-High to 4-High several times. Allow time between shifts to insure synchronizer is out of the 4-High mode before shifting. If vehicle exhibits high shifting effort in cold weather operation (below +30~F), but has reasonable effort and consistency after vehicle is warm, perform the front axle lubricant fill procedure as outlined later in this bulletin. If vehicle requires high shifting effort and shifts inconsistently after the front axle lubricant is warm, the following transfer case parts might require replacement, in addition to the front axle lubricant change. PARTS REQUIRED Transfer Case - NP208 ("W" and "AW" Truck) 1 Synchronizer Assembly PN 4329516 1 Drive Sprocket Assembly PN 4329527 Transfer Case - NP207 (N5 Dakota 4 x 4) 1 Synchronizer Assembly PN 4446457 1 Drive Sprocket Assembly PN 4446453 Front Axle Mopar High Performance Synthetic PN 4467707 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear, Transfer Case > Synchronizer Hub, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Synchronizer Hub: > 211587 > Aug > 87 > Transfer Case - High Effort Shifting From 2-H to 4-H > Page 3274 Axle Lube (1 quart can) REPAIR PROCEDURES This procedure involves replacing the synchronizer assembly and axle lube. Transfer Case See appropriate service manual for replacement procedures. Front Axle 1. Using a suction pump, remove as much of the axle lubricant as possible. NOTE: IT IS NOT NECESSARY TO REMOVE THE DIFFERENTIAL COVER. 2. Refill the axle with Mopar High Performance Synthetic Axle Lube, PN 4467707, as specified below. "W" and "AW" Truck: Fill to within 1/4" of the bottom of the fill plug hole (approximately 84 ounces). N5 Dakota 4 x 4: Fill to 1/2" below the bottom of the fill plug hole (approximately 40 ounces). NOTE: OVERFILL CAN RESULT IN LUBRICANT "FOAMING" AND/OR UNIT OVERHEATING. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Refer to Labor Operation Time Schedule for operation and time Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear, Transfer Case > Synchronizer Ring, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Synchronizer Ring: > 211587 > Aug > 87 > Transfer Case - High Effort Shifting From 2-H to 4-H Synchronizer Ring: Customer Interest Transfer Case - High Effort Shifting From 2-H to 4-H Models 1985-1987 "W" & "AW" Trucks With NP208 Transfer Case & "N" Body 4 x 4 With NP207 Transfer Case Subject High Shift Effort When Shifting From 2-High to 4-High Index TRANSMISSION Date August 17, 1987 No.. 21-15-87 (C10-21) P-2869 SYMPTOM/CONDITION High shift effort or total block out while shifting into 4-High (four-wheel drive transfer case). Condition occurs during cold weather operation while shifting the transfer case into 4-High from the 2-High mode. DIAGNOSIS With vehicle cold (below +30~F), shift transfer case from 2-High into 4-High with the vehicle stationary. It may be necessary to move vehicle slightly forward or rearward to engage front axle. If the transfer case does not shift with the vehicle stationary, check external shift linkage for proper adjustment (see appropriate service manual for transfer case shift linkage adjustment procedure). With vehicle still cold, attempt to shift from 2-High to 4-High at approximately 25 mph. While shifting, apply a constant force to the transfer case shift lever, not a quick pull. This will allow the synchronizer time to get the front propshaft up to speed. With cold front axle lubricant, the vehicle may require high effort for an extended time, or will not shift. Warm front axle lubricant by operating vehicle in 4-High mode for approximately 10 miles. Shift transfer case from 2-High to 4-High several times. Allow time between shifts to insure synchronizer is out of the 4-High mode before shifting. If vehicle exhibits high shifting effort in cold weather operation (below +30~F), but has reasonable effort and consistency after vehicle is warm, perform the front axle lubricant fill procedure as outlined later in this bulletin. If vehicle requires high shifting effort and shifts inconsistently after the front axle lubricant is warm, the following transfer case parts might require replacement, in addition to the front axle lubricant change. PARTS REQUIRED Transfer Case - NP208 ("W" and "AW" Truck) 1 Synchronizer Assembly PN 4329516 1 Drive Sprocket Assembly PN 4329527 Transfer Case - NP207 (N5 Dakota 4 x 4) 1 Synchronizer Assembly PN 4446457 1 Drive Sprocket Assembly PN 4446453 Front Axle Mopar High Performance Synthetic PN 4467707 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear, Transfer Case > Synchronizer Ring, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Synchronizer Ring: > 211587 > Aug > 87 > Transfer Case - High Effort Shifting From 2-H to 4-H > Page 3283 Axle Lube (1 quart can) REPAIR PROCEDURES This procedure involves replacing the synchronizer assembly and axle lube. Transfer Case See appropriate service manual for replacement procedures. Front Axle 1. Using a suction pump, remove as much of the axle lubricant as possible. NOTE: IT IS NOT NECESSARY TO REMOVE THE DIFFERENTIAL COVER. 2. Refill the axle with Mopar High Performance Synthetic Axle Lube, PN 4467707, as specified below. "W" and "AW" Truck: Fill to within 1/4" of the bottom of the fill plug hole (approximately 84 ounces). N5 Dakota 4 x 4: Fill to 1/2" below the bottom of the fill plug hole (approximately 40 ounces). NOTE: OVERFILL CAN RESULT IN LUBRICANT "FOAMING" AND/OR UNIT OVERHEATING. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Refer to Labor Operation Time Schedule for operation and time Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear, Transfer Case > Synchronizer Ring, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Synchronizer Ring: > 211587 > Aug > 87 > Transfer Case - High Effort Shifting From 2-H to 4-H Synchronizer Ring: All Technical Service Bulletins Transfer Case - High Effort Shifting From 2-H to 4-H Models 1985-1987 "W" & "AW" Trucks With NP208 Transfer Case & "N" Body 4 x 4 With NP207 Transfer Case Subject High Shift Effort When Shifting From 2-High to 4-High Index TRANSMISSION Date August 17, 1987 No.. 21-15-87 (C10-21) P-2869 SYMPTOM/CONDITION High shift effort or total block out while shifting into 4-High (four-wheel drive transfer case). Condition occurs during cold weather operation while shifting the transfer case into 4-High from the 2-High mode. DIAGNOSIS With vehicle cold (below +30~F), shift transfer case from 2-High into 4-High with the vehicle stationary. It may be necessary to move vehicle slightly forward or rearward to engage front axle. If the transfer case does not shift with the vehicle stationary, check external shift linkage for proper adjustment (see appropriate service manual for transfer case shift linkage adjustment procedure). With vehicle still cold, attempt to shift from 2-High to 4-High at approximately 25 mph. While shifting, apply a constant force to the transfer case shift lever, not a quick pull. This will allow the synchronizer time to get the front propshaft up to speed. With cold front axle lubricant, the vehicle may require high effort for an extended time, or will not shift. Warm front axle lubricant by operating vehicle in 4-High mode for approximately 10 miles. Shift transfer case from 2-High to 4-High several times. Allow time between shifts to insure synchronizer is out of the 4-High mode before shifting. If vehicle exhibits high shifting effort in cold weather operation (below +30~F), but has reasonable effort and consistency after vehicle is warm, perform the front axle lubricant fill procedure as outlined later in this bulletin. If vehicle requires high shifting effort and shifts inconsistently after the front axle lubricant is warm, the following transfer case parts might require replacement, in addition to the front axle lubricant change. PARTS REQUIRED Transfer Case - NP208 ("W" and "AW" Truck) 1 Synchronizer Assembly PN 4329516 1 Drive Sprocket Assembly PN 4329527 Transfer Case - NP207 (N5 Dakota 4 x 4) 1 Synchronizer Assembly PN 4446457 1 Drive Sprocket Assembly PN 4446453 Front Axle Mopar High Performance Synthetic PN 4467707 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear, Transfer Case > Synchronizer Ring, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Synchronizer Ring: > 211587 > Aug > 87 > Transfer Case - High Effort Shifting From 2-H to 4-H > Page 3289 Axle Lube (1 quart can) REPAIR PROCEDURES This procedure involves replacing the synchronizer assembly and axle lube. Transfer Case See appropriate service manual for replacement procedures. Front Axle 1. Using a suction pump, remove as much of the axle lubricant as possible. NOTE: IT IS NOT NECESSARY TO REMOVE THE DIFFERENTIAL COVER. 2. Refill the axle with Mopar High Performance Synthetic Axle Lube, PN 4467707, as specified below. "W" and "AW" Truck: Fill to within 1/4" of the bottom of the fill plug hole (approximately 84 ounces). N5 Dakota 4 x 4: Fill to 1/2" below the bottom of the fill plug hole (approximately 40 ounces). NOTE: OVERFILL CAN RESULT IN LUBRICANT "FOAMING" AND/OR UNIT OVERHEATING. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Refer to Labor Operation Time Schedule for operation and time Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Indicator Lamp: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3295 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3296 Fig. 14 Four Wheel Drive Indicator Lamp Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Technical Service Bulletins > Customer Interest for Transfer Case Actuator: > 020286 > Apr > 86 > Front Axle - No 4X4 Engagement Transfer Case Actuator: Customer Interest Front Axle - No 4X4 Engagement No. 02-02-86 P-1425 Date April 21, 1986 Index FRONT SUSPENSION Subject Front Axle Disconnect Will Not Engage Models 1985-1986 "W" & "AW" Models With Front Axle Disconnect SYMPTOM/CONDITION No engagement of four wheel drive after shift into "4H" or "4L". DIAGNOSIS Check the actuator at the front axle for vacuum lines being disconnected. If the lines are disconnected, it could be due to mud or snow packing around the vacuum motor and vacuum lines, and causing the vacuum lines to disconnect from the motor. REPAIR PROCEDURE This repair involves the installation of a revised vacuum motor shield. 1. Remove the present vacuum motor shield from the axle. 2. Reinstall vacuum lines and new clamps, PN 6032173, on vacuum motor. 3. Install new vacuum motor shield, PN 04384135. 4. Check vacuum motor for proper operation. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 02-60-05-90 0.3 Hrs. FAILURE CODE: 65 - Leaks Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transfer Case Actuator: > 020286 > Apr > 86 > Front Axle - No 4X4 Engagement Transfer Case Actuator: All Technical Service Bulletins Front Axle - No 4X4 Engagement No. 02-02-86 P-1425 Date April 21, 1986 Index FRONT SUSPENSION Subject Front Axle Disconnect Will Not Engage Models 1985-1986 "W" & "AW" Models With Front Axle Disconnect SYMPTOM/CONDITION No engagement of four wheel drive after shift into "4H" or "4L". DIAGNOSIS Check the actuator at the front axle for vacuum lines being disconnected. If the lines are disconnected, it could be due to mud or snow packing around the vacuum motor and vacuum lines, and causing the vacuum lines to disconnect from the motor. REPAIR PROCEDURE This repair involves the installation of a revised vacuum motor shield. 1. Remove the present vacuum motor shield from the axle. 2. Reinstall vacuum lines and new clamps, PN 6032173, on vacuum motor. 3. Install new vacuum motor shield, PN 04384135. 4. Check vacuum motor for proper operation. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 02-60-05-90 0.3 Hrs. FAILURE CODE: 65 - Leaks Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Technical Service Bulletins > Customer Interest: > 020286 > Apr > 86 > Front Axle - No 4X4 Engagement Transfer Case Actuator: Customer Interest Front Axle - No 4X4 Engagement No. 02-02-86 P-1425 Date April 21, 1986 Index FRONT SUSPENSION Subject Front Axle Disconnect Will Not Engage Models 1985-1986 "W" & "AW" Models With Front Axle Disconnect SYMPTOM/CONDITION No engagement of four wheel drive after shift into "4H" or "4L". DIAGNOSIS Check the actuator at the front axle for vacuum lines being disconnected. If the lines are disconnected, it could be due to mud or snow packing around the vacuum motor and vacuum lines, and causing the vacuum lines to disconnect from the motor. REPAIR PROCEDURE This repair involves the installation of a revised vacuum motor shield. 1. Remove the present vacuum motor shield from the axle. 2. Reinstall vacuum lines and new clamps, PN 6032173, on vacuum motor. 3. Install new vacuum motor shield, PN 04384135. 4. Check vacuum motor for proper operation. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 02-60-05-90 0.3 Hrs. FAILURE CODE: 65 - Leaks Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 020286 > Apr > 86 > Front Axle - No 4X4 Engagement Transfer Case Actuator: All Technical Service Bulletins Front Axle - No 4X4 Engagement No. 02-02-86 P-1425 Date April 21, 1986 Index FRONT SUSPENSION Subject Front Axle Disconnect Will Not Engage Models 1985-1986 "W" & "AW" Models With Front Axle Disconnect SYMPTOM/CONDITION No engagement of four wheel drive after shift into "4H" or "4L". DIAGNOSIS Check the actuator at the front axle for vacuum lines being disconnected. If the lines are disconnected, it could be due to mud or snow packing around the vacuum motor and vacuum lines, and causing the vacuum lines to disconnect from the motor. REPAIR PROCEDURE This repair involves the installation of a revised vacuum motor shield. 1. Remove the present vacuum motor shield from the axle. 2. Reinstall vacuum lines and new clamps, PN 6032173, on vacuum motor. 3. Install new vacuum motor shield, PN 04384135. 4. Check vacuum motor for proper operation. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 02-60-05-90 0.3 Hrs. FAILURE CODE: 65 - Leaks Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transfer Case Actuator: > 080887 > Mar > 87 > Map Lamp Mounting Tab Breakage Map Lamp: All Technical Service Bulletins Map Lamp - Mounting Tab Breakage Models 1982-1987 Domestic "D" & "W" Model Trucks & Sport Utility Vehicles Subject Map Lamp Tab Breakage Index ELECTRICAL Date March 2, 1987 No. 08-08-87 (C8-08) P-627 SYMPTOM/CONDITION Broken map lamp mounting tabs for the under dash mounted map lamp. PARTS REQUIRED Lamp Mounting Bracket Repair Package PN 4439009 REPAIR PROCEDURE This repair involves the installation of a map lamp retaining bracket. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transfer Case Actuator: > 080887 > Mar > 87 > Map Lamp Mounting Tab Breakage > Page 3331 FIGURE 1 Remove the instrument bezel in accordance with service manual procedures. Locate the repair bracket PN 4439009, over the broken lamp mounting tabs on the instrument panel, and below the existing mounting tabs for the instrument panel bezel.. The repair bracket should be positioned so that it will be retained by the instrument panel bezel retaining screws (Figure 1). Carefully reinstall the instrument panel bezel, making sure the replacement bracket does not come out of position. Secure the bezel and bracket with the bezel mounting screws. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 23-11-16-90 . . . . . . 0.4 Hrs. FAILURE CODE: 11 - Broken or Cracked Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transfer Case Actuator: > 080887 > Mar > 87 > Map Lamp Mounting Tab Breakage > Page 3337 FIGURE 1 Remove the instrument bezel in accordance with service manual procedures. Locate the repair bracket PN 4439009, over the broken lamp mounting tabs on the instrument panel, and below the existing mounting tabs for the instrument panel bezel.. The repair bracket should be positioned so that it will be retained by the instrument panel bezel retaining screws (Figure 1). Carefully reinstall the instrument panel bezel, making sure the replacement bracket does not come out of position. Secure the bezel and bracket with the bezel mounting screws. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 23-11-16-90 . . . . . . 0.4 Hrs. FAILURE CODE: 11 - Broken or Cracked Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Testing and Inspection Temperature Warning Indicator - A/T: Testing and Inspection Fig. 3 Recreational vehicle sensor package instrument cluster. 1980 Fig. 4 Recreational vehicle sensor package instrument cluster. 1981-82 The recreational vehicle sensor package consists of a separate instrument cluster, Figs. 3 and 4, which allows the driver to monitor the following conditions: engine oil level, engine coolant level, transmission fluid level and transmission fluid temperature. TROUBLESHOOTING VOLTAGE LIMITER TEST 1. Connect voltmeter between temperature sending unit (locating in fitting in bottom radiator tank) and a suitable ground. Do not disconnect electrical connector from sending unit. 2. Turn ignition switch to On position and observe voltmeter. 3. If voltmeter needle fluctuates, the voltage limiter is operating properly. 4. If voltmeter does not fluctuate, replace voltage limiter. The voltage limiter is located on the sensor panel. To gain access to the limiter, remove panel and unsnap the back cover. TEMPERATURE GAUGE TEST 1. Disconnect electrical connector from temperature sending unit in lower radiator tank. 2. Connect tester No. C-3826 or equivalent between temperature sending unit and a suitable ground. 3. Move tester pointer to ``C'' position, then turn ignition switch On and observe temperature gauge. Temperature gauge should read within 1/8 inch of ``C''. 4. Move tester pointer to ``M'' position. Temperature gauge should now advance to normal range left of 1/2 position on dial. 5. Move tester pointer to ``H'' position. Temperature gauge should now advance to ``H'' position on dial. 6. If temperature gauge responds to tests described in steps 3, 4 and 5, but does not operate when sending unit electrical connector is attached, the sending unit is defective and should be replaced. 7. If temperature gauge does not respond to tests described in steps 3, 4 and 5, check for loose connections, broken wire, open printed circuit or faulty gauge. OIL LEVEL PUSH BUTTON SWITCH 1. Inspect switch for poor solder connections and repair or replace as necessary. 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the switch should be replaced. To replace switch, Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Testing and Inspection > Page 3343 remove circuit board and push switch toward back of sensor housing. PRINTED CIRCUIT BOARD 1. Inspect conductors for cracks or damaged circuits. 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the sensor panel assembly should be replaced. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Indicator Lamp: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3349 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3350 Fig. 14 Four Wheel Drive Indicator Lamp Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding Brake Bleeding: Service and Repair About Brake System Bleeding WHEN BLEEDING BRAKES REMEMBER... - Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender covers to protect the vehicle's finish and electrical system. - Always flush and bleed the brake hydraulic sys. when servicing the brakes, because: Brake fluid absorbs moisture from the air, after 3-4 years of service the water content of the brake fluid may be as high as 6-7%. This significantly reduces the boiling point of the brake fluid which may result in a soft pedal or brake failure during prolonged or severe braking. Corrosion deposits and other contaminants gradually build up inside of the brake hydraulic sys. Check the bottom of the master-cylinder reservoir for a build up of fine black silt. If any is present the brake fluid should be flushed. - Never reuse brake fluid that has been drained from the brake system. DOT 3,4 or DOT 5 As a general rule DOT 5 brake fluid should not be used in vehicles recommending DOT 3 or 4 type fluid. DOT 5 brake fluid is silicone based. DOT 3 (standard) and DOT 4 (heavy-duty) are glycol-based. DOT 5 can be distinguished from conventional brake fluids by its purple color (which comes from a dye). DOT 5 silicone brake fluid won't mix with glycol-based brake fluid (creating concern over sludging if all old fluid isn't removed when a system is refilled with silicone). Silicone does not absorb moisture. DOT 5 brake fluid does not become contaminated with moisture over time as conventional DOT 3 and 4 brake fluids do. Silicone is also chemically inert, nontoxic and won't damage paint like conventional brake fluid. It also has a higher boiling point. Because of this, it is often marketed as a premium "lifetime" brake fluid. It is often used to preserve brake systems in antique vehicles and those that sit for long periods of time between use. Silicone also has slightly different physical properties and compressibility, making it unsuitable for ABS systems calibrated to work with DOT 3 or 4 brake fluid. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 3356 Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures Fig 2 Extending Valve Stem NOTE: All vehicles are equipped with a pressure hold-off valve. The valve is located (in the combination valve) on the left frame rail. The hold off valve balances front and rear braking force to improve braking and steering control on icy surfaces. The valve shuts off the flow of brake fluid between 3 and 135 PSI. Because the valve shuts off flow in this pressure range the valve must be held open manually -- using tool C-4121 or equivalent -- when pressure bleeding the system. CAUTION: Under no circumstances should a rigid clamp, wedge or block be used to depress the valve stem. This could cause an internal valve failure resulting in complete loss of front brakes. 1. Clean all dirt and foreign material from the cover of the master cylinder to prevent dirt from falling into the master cylinder reservoir when the cover is removed. 2. Install metering valve hands off tool, part No. C-4121 to valve stem of metering valve. NOTE: Complete bleeding of dual master cylinder is important before performing this procedure! 3. Starting with RWAL hydraulic valve, clean all dirt from the bleeder valve. 4. Place bleeder hose on the bleeder valve and insert the other end of the bleeder hose into a clear jar half filled with clean brake fluid. This will permit the observation of air bubbles as they are being expelled from the hydraulic system and also prevent air from being drawn back into the system. 5. Continue this bleeding with: a. The right rear wheel b. Then left rear wheel c. Next, bleed the right front and d. Finish with the left front wheel 6. Repeat this bleeding procedure if there is any indication of air remaining in the hydraulic system: - Spongy brake pedal - Warning light ON CAUTION: The pressure release valve is in its innermost position when there is no pressure present. No attempt should be made to further depress the valve stem. NOTE: If diagnosis determines that master cylinder alone is cause of trouble, it can be replaced without bleeding the hydraulic system provided the replacement cylinder is completely bled before installation. After brake tubes are connected have helper apply force to pedal while both tube nuts are cracked to release any air and then retightened. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 3357 Brake Bleeding: Service and Repair Pressure Bleeding (Preferred Procedure) Fig 2 Extending Valve Stem NOTE: All vehicles are equipped with a pressure hold-off valve. The valve is located (in the combination valve) on the left frame rail. The hold off valve balances front and rear braking force to improve braking and steering control on icy surfaces. The valve shuts off the flow of brake fluid between 3 and 135 PSI. Because the valve shuts off flow in this pressure range the valve must be held open manually -- using tool C-4121 or equivalent -- when pressure bleeding the system. CAUTION: Under no circumstances should a rigid clamp, wedge or block be used to depress the valve stem. This could cause an internal valve failure resulting in complete loss of front brakes. 1. Clean all dirt and foreign material from the cover of the master cylinder to prevent dirt from falling into the master cylinder reservoir when the cover is removed. 2. Install metering valve hands off tool, part No. C-4121 to valve stem of metering valve. NOTE: Complete bleeding of dual master cylinder is important before performing this procedure! 3. Starting with RWAL hydraulic valve, clean all dirt from the bleeder valve. 4. Place bleeder hose on the bleeder valve and insert the other end of the bleeder hose into a clear jar half filled with clean brake fluid. This will permit the observation of air bubbles as they are being expelled from the hydraulic system and also prevent air from being drawn back into the system. 4. Continue this bleeding with: a. The left rear wheel. b. Next, bleed the right front. c. Finish with the left front wheel. 6. Repeat this bleeding procedure if there is any indication of air remaining in the hydraulic system: - Spongy brake pedal - Warning light ON CAUTION: The pressure release valve is in its innermost position when there is no pressure present. No attempt should be made to further depress the valve stem. NOTE: If diagnosis determines that master cylinder alone is cause of trouble, it can be replaced without bleeding the hydraulic system provided the replacement cylinder is completely bled before installation. After brake tubes are connected have helper apply force to pedal while both tube nuts are cracked to release any air and then retightened. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair Brake Pedal Assy: Service and Repair Fig 1 Power Brake Mounting And Related Parts REMOVAL 1. From under instrument panel, position a small screwdriver between the center tang on the retainer clip and the pin in the brake pedal. 2. Rotate screwdriver enough to allow retainer clip center tang to pass over end of brake pedal pin and pull clip and push rod from pin. Discard retainer clip. 3. Remove retainer screw and locknut from end of pedal shaft. 4. Slide pedal shaft out of housing and remove brake pedal assembly. INSTALLATION 1. Position brake pedal assembly and slide pedal shaft into position. 2. Install retainer screw and tighten locknut to 35 in lb (4 Nm). 3. Connect push rod to pedal pin and install new retainer clip. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Caliper Adapter To Steering Knuckle 110 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Testing and Inspection > With Caliper On Vehicle Brake Caliper: Testing and Inspection With Caliper On Vehicle Fig 9 Caliper Assembly Check for piston seal leaks (evident by brake fluid in and around boot area and inboard lining) and for any ruptures of piston dust boot. If boot is damaged, or fluid is evident, it will be necessary to disassemble caliper assembly and install a new seal, boot, (and piston if damaged or corroded). Check the mating surfaces of the abutments on the caliper and adaptor. If corroded or rusty, clean surfaces with wire brush. Inspect braking surfaces of disc. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Testing and Inspection > With Caliper On Vehicle > Page 3367 Brake Caliper: Testing and Inspection With Caliper Removed WITH CALIPER ON VEHICLE Check for piston seal leaks (brake fluid in and around boot area and inboard lining) and for any ruptures of piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper assembly and install a new seal and boot, (and piston if corroded or scored). Check the mating surfaces of the abutments on the caliper and adapter. If corroded or rusty, clean surfaces with wire brush. Inspect braking surfaces of disc. Check dust boots for punctures or tears. If punctures or tears are evident, new boots should be installed upon reassembly.. WITH CALIPER REMOVED Cleaning Clean all parts using alcohol or a suitable solvent and blow dry, using compressed air. Blow out all drilled passages and bores. NOTE: Black stains on the bore walls are caused by piston seals and will do no harm. Inspect the piston bore for scoring or pitting Bores that show light scratches or corrosion, can usually be cleared with crocus cloth. - Bores that have deep scratches or scoring should be honed, providing the diameter of the bore is not increased more than 0.002 inch. - If the bore does not clean up within this specification, a new caliper housing should be installed. Install a new piston if the old one is pitted or scored. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation Removal For additional information see Fundamentals and Basics. See: Fundamentals and Basics Fig 3 Adaptor And Caliper Machined "Ways" And Caliper Retention NOTE: It may be necessary to remove fluid to put in new linings as fluid is pushed back into the master cylinder. NOTE: It is necessary to remove the caliper to install a new piston seal and boot. 1. Raise the vehicle on jackstands or hoist. 2. Remove front wheel covers and wheel and tire assemblies. 3. Disconnect flexible brake hose from caliper. If pistons are to be removed from caliper leave brake hose connected to caliper. 4. Plug brake tube to prevent loss of fluid, or prop brake pedal to any position below first inch of travel. 5. Disconnect hose from caliper. 6. Remove retaining screw, retaining clip (and anti-rattle spring) that attach caliper to adaptor. Fig 6 Removing Or Installing Caliper 7. Carefully slide caliper out and away from disc and adaptor. Installation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3370 For additional information see Fundamentals and Basics. See: Fundamentals and Basics NOTE: Examine linings for wear, damage or fluid contamination if linings are satisfactory they may be reused. - If not usable both front brakes must be relined with new lining. - If old linings are to be reused, be sure linings are installed in their original position. 1. Slide new outboard shoe and lining assembly in recess of caliper. CAUTION: No free play between brake shoe flanges and caliper fingers should exist (which might cause brake shoe rattle). Fig. 7 Bending Outboard Pad Retaining Flange Fig 12 Attaching Shoe To Caliper Fingers With C-clamp NOTE: If free play is evident by vertical shoe movement after installation, remove shoe from caliper and bend flanges to create slight interference fit to eliminate all vertical free play when shoe is installed. Install shoe after above modification, if necessary, by snapping shoe into place with fingers or with light "C" clamp, protect new lining from damage or contamination by using old pads over new lining and across caliper fingers. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3371 Fig 8 Removing Or Installing Shoe 2. Position inboard shoe in position on adaptor with shoe "flanges" in the adaptor "ways". 3. Slowly slide caliper assembly into position in adaptor and over disc. - Align caliper on machined ways of adaptor. - Be careful not to pull the dust boot from its groove as the piston and boot slide over the inboard shoe. 4. Install anti-rattle springs and retaining clips and torque retaining screws to 200 inch-pounds. Fig 3 Adaptor And Caliper Machined "Ways" And Caliper Retention NOTE: The inboard shoe anti-rattle spring must always be installed on top of the retainer spring plate. 5. With bleeder screw open, allow caliper to "Gravity" fill with brake fluid, then close bleeder screw. (Be sure all air bubbles have escaped; replenish brake fluid in master cylinder. Bleed brakes. 6. Pump brake pedal several times until a firm pedal has been obtained. 7. After bleeding caliper, check for fluid tightness under maximum pedal pressures. (Recheck master cylinder reservoir level). 8. Install wheel and tire assembly. 9. Remove jackstands or lower hoist. 10. Road test vehicle and make several stops to wear off any foreign material on the brakes and to seat the linings. - The vehicle may pull to one side or the other if this is not done. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3372 Brake Caliper: Service and Repair Disassembly and Assembly Disassembly Fig 3 Adaptor And Caliper Machined "Ways" And Caliper Retention 1. Raise vehicle, remove wheel and tire assemblies. 2. Remove retaining screw, retaining clip (and anti-rattle spring) that attach caliper to adaptor. Fig 6 Removing Or Installing Caliper 3. Carefully slide caliper out and away from disc and adaptor. 4. Remove outboard shoe and lining assembly from caliper. 5. To remove piston, support caliper assembly on upper control arms on shop towels to absorb any hydraulic fluid loss. a. Carefully depress brake pedal to hydraulically push piston out of bore (brake pedal will fall away when piston has passed bore opening) b. Prop brake pedal to any position below the first inch of pedal travel to prevent loss of brake fluid. (If both front caliper pistons are to be removed, disconnect flexible brake line at frame bracket after removing first piston. Plug brake tube to remove piston from opposite caliper.) CAUTION: Under no condition should air pressure be used to remove piston from bore. Personal injury could result from such practice. 6. Disconnect brake flexible hose from the caliper. 7. Mount caliper assembly in a vise equipped with protector jaws. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3373 CAUTION: Excessive vise pressure will cause bore distortion and binding of piston. 8. Remove dust boot using suitable tool. Fig. 11 Piston Seal Removal 9. Using a small, pointed, wooden or plastic stick, work piston seal out of its groove in piston bore. Discard old seal. CAUTION: Do not use a screwdriver or other metal tool for this operation, because of possibility of scratching piston bore or burring edges of seal groove. Assembly Fig. 12 Piston Seal Installation 1. Clamp caliper in vise (with protector jaws). CAUTION: Excessive vise pressure will cause bore distortion and binding of piston. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3374 2. Dip new piston seal in clean brake fluid and install in groove in bore. Seal should be positioned at one area in groove and gently worked around the groove, using fingers, until properly seated. Make sure that fingers are clean. Never use an old piston seal. (Be sure seal is not twisted or rolled). 3. Coat new piston boot with clean brake fluid leaving a generous amount inside of boot. 4. Position dust boot over piston. Fig 16 Installing Piston Through Boot 5. Install piston into bore pushing it past the piston seal until the piston bottoms in the bore. Fig. 13 Dust Boot Installation 6. Position the dust boot in the counterbore. Using a hammer and Tool C-4690 with handle C-4171, or equivalent, drive the boot onto the counterbore. CAUTION: Force must be applied uniformly to avoid cocking. 7. Install brake hose to caliper using new seal washers. NOTE: Before installing caliper assembly on vehicle, inspect braking disc runout and thickness. Cleaning, Inspecting & Honing Caliper Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3375 Fig 14 Honing Piston Bore Clean all parts using alcohol or a suitable solvent and blow dry, using compressed air. Blow out all drilled passages and bores. NOTE: Whenever a caliper has been disassembled, a new boot and seal must be installed at reassembly. Inspect the piston bore for scoring or pitting. Install a new piston if it is pitted, scored or the plating is severely worn. - Bores that show light scratches or corrosion, can usually be cleared with crocus cloth. - Bores that have deep scratches or scoring should be honed, using Tool C-4095, or equivalent, providing the diameter of the bore is not increased more than 0.002 inch (0.050mm). - If the bore does not clean up within this specification, a new caliper housing should be installed. NOTE: Black stains on the piston are caused by the piston seal and will do no harm. When using Hone C-4095 or equivalent, coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with stiff non-metallic rotary brush. CAUTION: Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the caliper with brake fluid; wipe dry with a clean, lintless cloth and then clean a second time in the same manner or until clean cloth shows no signs of discoloration. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes Brake Caliper: Fundamentals and Basics Removal Notes When Removing the Caliper, Remember... - Prior to removing the calipers, remove/siphon brake fluid from master-cylinder until the reservoir is only 1/3 full. - Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender covers to protect the vehicle's finish and electrical system. - Always replace all brake linings on an axle. Never replace only one wheel. Unequal lining thickness between wheels on the same axle will result in a strong steering pull when the brakes are applied. - Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. - When forcing the piston back into the caliper, open the bleeder valve first. Corrosion and other deposits accumulate inside of the caliper. If the bleeder valve is not opened when the piston is forced back into the caliper, these deposits will be forced back through the brake lines and into the master-cylinder. - When pushing the pistons back into the caliper with the bleeder screw open, a stream of brake fluid will be expelled from the bleeder screw for 2-3 feet. Use a drip pan and be careful not to "shoot" brake fluid onto the vehicle's finish. A cleaner method is to use a piece of clear plastic hose and a glass or plastic jar to catch the expelled fluid. - Upon removal, Do Not allow the calipers to hang by the flexible brake hoses. The brake hoses can be damaged easily by this practice. These hoses are double walled, damage to the interior pressure hose will not be visible. - Do not depress the brake pedal with either caliper removed from the rotor. The caliper pistons will be inadvertently expelled from the caliper. If this occurs rebuild or replace the caliper, do not attempt to insert the piston back into the caliper. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 3378 Brake Caliper: Fundamentals and Basics Installation Notes WHEN INSTALLING CALIPERS AND PADS, REMEMBER... - Clean and lubricate caliper slide joint/pins with high temperature silicone grease: Unlike drum brakes, disc brakes do not utilize a spring to withdraw the pads/linings when the brake pedal is released. Disc brakes rely on the elasticity of the piston seals, and the unrestricted movement of the caliper slide assemblies to release the brakes. If the slide joints/pins are not cleaned and lubricated properly the disc brake linings will drag upon the release of the brake pedal. This will result in overheated brakes and premature brake wear. Disc Brake Mechanical Force Diagram NOTE: Floating calipers require free and unrestricted movement on the caliper mounting. Floating or sliding calipers have pistons only on one side of the rotor. The first part of the piston's travel forces the inner pad against the rotor, then further travel forces the movable part of the caliper to pull the outer pad against the rotor. High temperature silicone lubricant must be used. Low temperature grease can melt and contaminate the pads and rotors, or can bake into a very hard substance which binds the slides. Petroleum based grease can cause the slide boots to soften and swell. - Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. Anti-squeal Coating - Apply an anti-squeal coating to the back side of the pads/linings. This coatings acts as an insulator to dampen high frequency vibrations that are generated during normal braking. These compounds are highly effective in preventing brake squeal. - Many professional repair shops recommend always rebuilding or replacing the calipers when replacing the brake linings, because: When the pistons are forced back into the calipers, the piston seals are dragged across any corrosion or abrasives that may be deposited on the inside of the caliper. Damage to the seals may not be initially evident. As the new brake linings begin to wear, the piston is gradually withdrawn from the caliper. This results in the piston seals again being dragged across the layer of corrosion and deposits. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 3379 Calipers which are not rebuilt or replaced have a higher probability of sticking or leaking. - Check to ensure the bleeder screw is not frozen prior to reinstalling caliper. Freeing a stuck bleeder screw is much easier with the caliper removed from the vehicle. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service Precautions Brake Pad: Service Precautions Do not get any oil or grease on the linings. It is recommended that both front wheel sets be replaced whenever a respective shoe and lining is worn or damaged. Inspect and, if necessary, replace rear brake linings also. If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation Brake Pad: Service and Repair Removal and Installation Removal Fig 3 Adaptor And Caliper Machined "Ways" And Caliper Retention NOTE: It may be necessary to remove fluid to put in new linings as fluid is pushed back into the master cylinder. 1. Raise vehicle on a hoist or jackstands. 2. Remove front wheel covers, and wheel and tire assemblies. 3. Force piston back into caliper bore by pulling outward on the caliper assembly 4. Remove caliper retaining clips and anti-rattle springs. Fig 6 Removing Or Installing Caliper 5. Remove caliper from disc by slowly sliding caliper assembly out and away from disc. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 3385 Fig 7 Removing Outboard Shoe Fig 8 Removing Or Installing Shoe 6. Remove outboard shoe (flanges on outboard shoe will retain shoe to caliper) by prying between shoe and caliper fingers. Support caliper so as not to damage flexible brake hose. Remove inboard brake shoe. Installation NOTE: It may be necessary to remove fluid to put in new linings as fluid is pushed back into the master cylinder. 1. Slowly and carefully push piston back into bore until it is bottomed. Watch for possible reservoir overflow. 2. Slide new outboard shoe and lining assembly in recess of caliper after removing paper from noise suppression gasket. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 3386 Fig 10 Caliper And Outboard Shoe Retainer Flange Fig. 7 Bending Outboard Pad Retaining Flange Fig 12 Attaching Shoe To Caliper Fingers With C-clamp NOTE: No free play between brake shoe flanges and caliper fingers should exist (which might cause brake shoe rattle). If free play is evident by vertical shoe movement after installation, remove shoe from caliper and bend flanges to create slight interference fit to eliminate all vertical free play when shoe is installed. - Install shoe after above modification, if necessary, by snapping shoe into place with fingers or with light "C" clamp, protect new lining from Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 3387 damage or contamination by using old pads over new lining and across caliper fingers. Fig 8 Removing Or Installing Shoe 3. Remove paper from noise suppression gasket and then position inboard shoe in position on adaptor with shoe "flanges" in the adaptor "ways". 4. Slowly slide caliper assembly into position in adaptor and over disc. Align caliper on machined ways of adaptor. CAUTION: Be careful not to pull the dust boot from its groove as the piston and boot slide over the inboard shoe. 5. Install anti-rattle springs and retaining clips and torque retaining screws to 200 in lb. Fig 3 Adaptor And Caliper Machined "Ways" And Caliper Retention NOTE: The inboard shoe anti-rattle spring must always be installed on top of the retainer spring plate. 6. Pump brake pedal several times until a firm pedal has been obtained. 7. Check and refill master cylinder reservoirs (if necessary) with DOT 3 brake fluid as required. NOTE: It should not be necessary to bleed the system after shoe and lining removal and installation. However, if a firm pedal cannot be obtained bleed the brake system. 8. Install wheel and tire assemblies and wheel covers. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 3388 9. Remove jack stands or lower hoist. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Removal and Installation > Page 3389 Brake Pad: Service and Repair Cleaning and Inspection Remove one of the front wheels and inspect the brake disc, caliper and linings. The wheel bearings should be inspected at this time and repacked if necessary. Do not get any oil or grease on the linings. It is recommended that both front wheel sets be replaced whenever a respective pad is worn or damaged. Inspect and, if necessary, replace rear brake linings also. If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Specifications > Front Brake Disc: Specifications Front Nominal Thickness 3300 lb. Axle 1.25 in 4000 lb. Axle 1.19 in Minimum Thickness 3300 lb. Axle 1.180 in 4000 lb. Axle 1.125 in Thickness Variation (Parallelism) 0.001 in Run Out (TIR) 0.005 in Finish 15-80 micro-in Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Specifications > Front > Page 3394 Brake Disc: Specifications Models With 4000 Lb Front Axles Nominal Thickness 1.17-1.19 in Minimum Thickness Note: Use minimum thickness Specification stamped on rotor hub. Thickness Variation (Parallelism) 0.001 in Runout (TIR) 0.005 in Finish 15-80 micro-in Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Specifications > Page 3395 Brake Disc: Testing and Inspection PURPOSE In the manufacturing of the brake rotor all the tolerances regarding surface finish, parallelism, and lateral runout are held very closely. The maintenance of these tolerances provide the surface necessary to prevent brake roughness. Light scoring of the rotor surface not in excess of 0.38 mm (0.015-inch) in depth is normal. This condition does not affect the brake operation. Some discoloration or wear of the disc surface is normal and does not require re-surfacing when linings are replaced. SPECIFICATIONS - See: Specifications LATERAL RUNOUT Lateral runout is the movement of the rotor from side to side as it rotates on the spindle. This could also be referred to as "rotor wobble". This movement causes the brake pad and piston to be knocked back into it's bore. This results in additional pedal travel and a vibration during braking. Checking Lateral Runout 1. Tighten the wheel bearings to eliminate all freeplay. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Specifications > Page 3396 2. Attach a dial indicator to a solid non-rotating portion of the hub assembly or suspension. - The point of the styles must contact the rotor face about 25 mm (1-inch) from the rotor edge. 3. Move the rotor one complete rotation and observe the dial indicator. 4. Rotate the bezel on the dial indicator such that "0" is at the low deflection point. 5. Again rotate the rotor at least one complete turn and observe the needle deflection. Total needle deflection will equal lateral runout. 6. Readjust the wheel bearings. MINIMUM THICKNESS The thickness of a rotor is important for two reasons: 1. Rotors which are too thin are not able to properly absorb and release heat during heavy braking. This results in reduced braking capacity and brake fade. 2. Rotors worn below minimum thickness in combination with worn pads/linings can result in the caliper piston extending too far becoming cocked or jammed. Rotor thickness should be measured at the thinnest point on the rotor. Any rotor which is worn below its minimum thickness should be replaced. For accurate measurements, it is best to remove the caliper to allow for complete access to the inboard side of the rotor. For more information on how to use a disc brake micrometer see Fundamentals and Basics. See: Fundamentals and Basics Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Specifications > Page 3397 PARALLELISM Parallelism is the measurement of the thickness of the rotor at 12 or more points around the circumference of the rotor. All measurements must be made at the same distance in from the edge of the rotor. Lack Of Parallelism Lack Of Parallelism MACHINING Since accurate control of the rotor tolerances is necessary for proper performance of the disc brakes, machining of the rotor should be done only with precision equipment. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Specifications > Page 3398 All brake rotors have a minimum thickness dimension cast into them. This dimension is the minimum wear dimension and not a refinish dimension. Do not use a brake rotor that will not meet the specifications, after refinishing. Replace with a new brake rotor. NOTE: 1 inch = 25.4mm, so if your micrometer measures in inches and the specified thickness on the disc is in millimeters, convert millimeters to inches by dividing the specified number of millimeters by 25.4. Example: Specification on disc is 17.8 mm. Dividing 17.8mm by 25.4mm/in = 17.8/25.4 = 0.70 inches. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Service and Repair > Rotor Removal and Installation Brake Disc: Service and Repair Rotor Removal and Installation Removal Fig 3 Adaptor And Caliper Machined "Ways" And Caliper Retention Fig 6 Removing Or Installing Caliper 1. Raise and support vehicle on hoist or jackstands. 2. Remove wheel cover and wheel and tire assembly. 3. Remove caliper assembly, but do not disconnect brake line. - Suspend caliper from wire hook to avoid strain on flexible hose. 3. Remove grease cap, cotter pin, nut lock, nut thrust washer and outer wheel bearing. 4. Pull disc and hub off wheel spindle. Installation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Service and Repair > Rotor Removal and Installation > Page 3401 Fig 3 Adaptor And Caliper Machined "Ways" And Caliper Retention Fig 6 Removing Or Installing Caliper 1. Slide brake disc and hub assembly on spindle. 2. Install outer bearing, thrust washer and nut. 3. Tighten wheel bearing adjusting nut to 90 inch lb while rotating disc and hub. 4. Check disc runout. 5. Back off adjusting nut to release all preload, then retighten adjusting nut finger tight. 6. Position lock nut on nut with one pair of slots in line with cotter pin hole. Install and lock cotter pin. 7. Clean grease cap and coat inside with wheel bearing grease (do not fill cap) and install cap. 8. Clean both sides of disc with alcohol or suitable solvent. 9. Install caliper assembly. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Service and Repair > Rotor Removal and Installation > Page 3402 Brake Disc: Service and Repair Rotor Refinishing CAUTION: Servicing of disc brakes is extremely critical due to the close tolerances required in machining the brake disc to insure proper brake operation. Tolerance and Precision The maintenance of these close controls on the friction surfaces is necessary to prevent brake roughness. In addition, the surface finish must be non-directional and maintained at a micro-inch finish. This close control of the rubbing surface finish is necessary to avoid pulls and erratic performance and promote long lining life and equal lining wear of both left and right brakes. In light of the foregoing remarks, refinishing of the rubbing surfaces should not be attempted unless precision equipment, capable of measuring in micro-inches (millionths of an inch) is available. Resurfacing Braking Disc This operation can be used when the disc surface is rusty or has lining deposits. A sanding disc attachment will remove surface contamination without removing much material. It will generally follow variations in thickness which are in the disc. Fig 2 Refacing Brake Disc Refacing Braking Disc Rotors do not have to be refaced every time a disc brake is relined. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Service and Repair > Rotor Removal and Installation > Page 3403 - If the rotor surface is deeply scored or warped or there is a complaint of brake roughness the rotor should be refaced. When refacing a disc brake rotor the required TIR (Total Indicator Reading) and thickness variation MUST BE MAINTAINED. CAUTION: If the disc is not mounted properly the runout will be worse after refacing than before refacing. Extreme care in the operation of rotor turning equipment is required. The use of a double straddle cutter which machines both sides of the disc at the same time is mandatory. - When mounting the disc on the lathe strict attention to the manufacturer's instructions is required. - The collets, shafts and adaptors on the lathe and the bearing cups in the rotor MUST be clean and free from any chips or contamination. Fig 3 Disc Measurement Points DO NOT reface a disc brake rotor more than 0.030 inch less than the original disc minimum thickness. Reface both sides of rotor, not exceeding 0.030" total. All rotors (disc) will show marking of minimum allowable thickness cast on the un-machined surface. This marking includes 0.030 inch (0.762mm) allowable rotor wear beyond the recommended 0.030 inch (0.762mm) of disc refacing. Example: Minimum Allowable Thickness 0.940 (23.8mm) - Allow for Wear 0.030 (0.762mm) - Do Not Reface Beyond 0.970 (24.6mm) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints Brake Disc: Fundamentals and Basics Notes, Warnings, and Hints WHEN INSTALLING A ROTOR/DISC, REMEMBER... Thoroughly clean the rotors with brake cleaner. - Any grease or brake fluid which comes in contact with the rotor should be thoroughly cleaned prior to installing the new pads/linings. - Grease and other contaminants become lodged in the microscopic pores of the rotor's surface. This prolongs the brake-in time of the new linings and contaminates the friction material. - Commercially produced aerosol brake cleaners should be used to clean the rotor. Unlike carburetor cleaner or other petroleum based solvents, brake cleaner does not leave a residue on the rotor's surface. Recheck the wheel bearings once the tires are installed. - With the vehicle raised and properly supported, grasp the tire at the top and bottom and attempt to rock them back and forth. There should be no detectable lateral (wobble) movement. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 3406 Brake Disc: Fundamentals and Basics How to Use A Micrometer CONSTRUCTION The spindle on a micrometer is moved in or out by rotating the thimble or ratchet. The thread pitch on the spindle is 40 threads per inch. A single full rotation of the thimble extends or retracts the spindle one thread or 1/40 of an inch (0.025, 25 thousands). The thimble is divided into 25 equal divisions. Rotating the thimble one division will extend or retract the spindle 1/25 of a thread. (1/25) x (1/40)inch = 1/1000 inch (0.001), one division on the thimble is equal to 0.001 inches. HOW TO READ As the thimble is rotated out it uncovers a scale on the sleeve. Each major division on the scale is 1/10 of an inch (0.100) Each major division is separated into 4 minor divisions, each equal to 25/1000 of an inch (0.025). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 3407 A full rotation will move the thimble exactly one minor division on the sleeve. To read the micrometer you must add the measurement which is visible on the sleeve to the measurement which is showing on the thimble In the example the sleeve measurement is 0.250 inches and the thimble measurement is 0.017 inches. The total measurement is then equal to the two measurements combined, 0.267 inches. NOTES The accuracy and calibration of a micrometer can be altered easily by applying too much pressure to the spindle. Use the thimble to quickly rotate the spindle in until it is near the rotor. - Use the ratchet to rotate the spindle into contact with the rotor. - The ratchet has a built in slip which prevents excessive stress or pressure from developing. Calibrate the micrometer regularly. Most micrometers come with a precision dowel which allows for easy and accurate adjustments. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 3408 Brake Disc: Fundamentals and Basics Tightening Notes WHEN TIGHTENING LUG NUTS, REMEMBER... Always tighten the lug nuts to the correct torque specification. Lightly lubricate the studs with an anti-seize compound to ensure proper torque and prevent damage to the threads. Tighten in an alternating pattern around the wheel until the wheel is centered on the studs. Do your final tightening with a torque wrench. When servicing disc brakes it is very important to properly torque the wheel assembly. Lug nuts which are installed with an air impact tool are often over-torqued. This may distort the rotor and result in excessive lateral runout (rotor wobble) and a pedal pulsation upon braking. Recheck the wheel bearings once the tires are installed. With the vehicle raised and properly supported, grasp the tire at the top and bottom and attempt to rock them back and forth. There should be no detectable lateral (wobble) movement. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 3409 Brake Disc: Fundamentals and Basics Wheel Bearing Inspection and Repacking WHEEL BEARING INSPECTION Inspect the wheel bearing closely for the following: Fatigue Spalding Look for small flakes of shiny metal (babbit) embedded in the grease. This can easily be done by dragging the bearing across a clean shop towel. Any metal flakes will be readily visible in the grease deposited on the shop towel. If any flakes are found the wheel bearing should be replaced. Brinelling Look for a series of vertical indentations on the races. This is caused by impact loading or vibration while the bearing is not rotating. Replace the bearing if the indentations are severe or the bearing is noisy. Heat Discoloration Heat discoloration can range from faint yellow to dark blue. This results from the bearing being adjusted too tightly or an insufficient amount of lubricant/grease. Excessive heat can cause the races and rollers to soften. To check for a loss of temper on the races or rollers a simple file test may be performed. A file drawn lightly over a race or roller which has lost its case hardening will grab and cut metal, whereas a file drawn lightly over a hardened part will glide readily without scratching the metal. Replace the bearing and race if softening is indicated. Cracked Outer Race Cracked races often result from the race being driven in cocked or at an angle. Replace the bearing and race and be careful to drive the new race in evenly. Loose Outer Race Check to see that the race is tight and secure in the hub. If there is any evidence of movement or slippage, replace both the hub assembly and the bearing. Bent or Damaged Cage Verify that the cage has not been bent or distorted. Bent or damaged cages are often the result of improper bearing and grease seal removal techniques. When removing the inner wheel bearing use a seal puller to remove the grease seal. The inner bearing should then just slide out of the hub. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 3410 Do not re-install the spindle nut and attempt to slide-hammer the grease seal from the hub. WHEEL BEARING REPACKING - The hub and spindle should be thoroughly cleaned of all old grease. - The bearings should be cleaned in solvent and allowed to dry completely. WARNING: Do not spin dry the bearings with compressed air, this practice can rapidly damage bearings. - If possible use a commercial wheel bearing packer, otherwise repack the bearings by hand. Hand Repacking Place a quantity of high-temperature, multi purpose wheel bearing grease in the palm of your hand. - Cup the bottom of the bearing cage (the wider end) into the palm of your hand forcing grease up through the cage. Repeat the procedure until the new grease is pushed out of the top of the cage. - Repeat this around the entire circumference of the bearing. - Apply a coating of new wheel bearing grease to the spindle and the inside of the hub. NOTE: The hub should not be completely packed with new grease. As the brakes are applied the hub will heat up and the grease will expand. If an excessive amount of grease is prepacked into the hub, upon heating it will force its way past the grease seals and contaminate the brake system. - Also apply a thin coating of grease to the inside lip of the new grease seals. NOTE: The side of the grease seal from which the spring is visible should point towards the bearing. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications Backing Plate: Specifications Rear wheel brake support to axle housing bolt nut 7/16" .................................................................................................................................................... .............................................. 75 ft lb (101 Nm) 1/2" ........................................................................... ......................................................................................................................... 85 ft lb (115 Nm) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 3415 Backing Plate: Testing and Inspection Inspect backing plate shoe contact surface for grooves that may restrict shoe movement and cannot be removed by lightly sanding with emery cloth or other suitable abrasive. If backing plate exhibits above condition, it should be replaced. Also inspect for signs of cracks, warpage and excessive rust, indicating need for replacement. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 3416 Backing Plate: Service and Repair Fig 3 Removing Brake Cable From Support Plate REMOVAL 1. With wheel and brake drum removed, remove brake shoe assemblies and disconnect brake cable. 2. Using a suitable tool such as an aircraft-type hose clamp, compress the flared legs of cable retainer and pull brake cable out of support plate. 3. Disconnect hydraulic brake tube from wheel cylinder. 4. Remove support plate to wheel cylinder attaching nuts and washers. 5. Remove rear axle shaft and retainer. 6. Remove brake support plate from rear axle housing. INSTALLATION 1. Install support plate onto rear axle housing. 2. Insert rear axle shaft and retainer into housing and install axle retainer nuts and washers. - Rear wheel brake support to axle housing bolt nut 7/16" .................................................................. ........................................................................................................................ 75 ft lb (101 Nm) 1/2" . .............................................................................................................................................................. ............................. 85 ft lb (115 Nm) 3. Install wheel cylinder and attach hydraulic brake tube. 4. Insert parking brake cable into support plate and attach cable to parking brake lever. 5. Install brake shoes on support plate. 6. Install brake drum and wheel. 7. Adjust and bleed brakes. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Adjuster > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Brake Adjuster: Initial Inspection and Diagnostic Overview ADJUSTER MECHANISM Inspect all components for rust, corrosion, bends and fatigue. Replace as necessary. On adjuster mechanism equipped with adjuster cable, inspect cable for kinks, fraying or elongation of eyelet and replace as necessary. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Adjuster > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3421 Brake Adjuster: Component Tests and General Diagnostics Fig. 6 Release type brake adjuster 1. Place the vehicle on a hoist, with a helper in the driver's seat to apply the brakes. 2. Remove the access plug from the rear adjustment slot in each brake support plate to provide access to the adjuster star wheel. NOTE: It will be necessary to hold the adjuster lever away from the star wheel to permit the following adjustment. 3. Back the star wheel off approximately 30 notches. - This eliminates the possibility of maximum adjustment, whereby the adjuster does not operate because the closest possible adjustment has been reached. 4. Spin the wheel and brake drum in the reverse direction and -- with greater than normal force -apply the brakes suddenly. - This sudden application of force will cause the secondary brake shoe to leave the anchor. The wrap up effect will move the secondary shoe, and the cable will pull the adjuster lever up. - Upon application of the brake pedal, the lever should move upward, turning the star wheel. - Thus, a definite rotation of the adjuster star wheel can be observed if the automatic adjuster is working properly. - If one or more adjusters do not function properly, the respective drum must be removed for adjuster servicing. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications Rear Inside Diameter 12.0 in Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 3425 Brake Drum: Testing and Inspection VISUAL INSPECTION Inspect the drum for cracks. If any large, through-the-drum cracks are located the drum must be replaced. NOTE: Cracks in drums are often difficult to locate. To quickly determine if a drum is cracked lightly drop the drum (from a height of 4-5 inches) onto a flat hard surface. A cracked drum will make a dull thud sound while a good drum will make a ringing sound. Inspect for signs of overheating. An overheated drum will often be discolored (blue/gold), warped, or heat checked. Heat checks are small cracks in the drum friction surface. If drums are cracked or heat spotted, they must be replaced. NOTE: The cause of the overheating should be determined prior to replacing the shoes/linings or drums. Inspect for scoring. Any grooves or scores in excess of 0.008 inches should be resurfaced. SPECIFICATIONS - See: Specifications MAXIMUM DIAMETER Purpose The thickness of the drum friction surface is directly proportional to the drums ability to absorb and release heat during braking. As the drum becomes thinner due to normal wear and resurfacing it looses its ability to absorb and release heat and is more prone to brake fade, distortion, and cracking. As the drum wears the inside diameter of the drum increases. The amount of drum thickness lost to wear is equal to 1/2 the increase in diameter. There are two specifications related to drum thickness. Discard Diameter - This is the maximum diameter at which it becomes unsafe to operate. A drum which has reached this thickness should not be machined and should be discarded. Maximum Refinish - This is the maximum diameter to which a drum may be machined or resurfaced to. This diameter is smaller (thicker) than the Discard diameter because it assumes the drum will need to have a sufficient thickness left, after machining, to allow for further wear from a new set of shoes/linings. Which One Should Be Used? If you install a new pair of shoes with the drum diameter at or less than the "Maximum Refinish" specification the drums should have a sufficient thickness to last the normal life of the new shoes/linings. The "Discard Diameter" should be used to determine if a drum needs to be replaced at the present time of inspection. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 3426 If you install a new pair of shoes with the drums machined at or near "Discard Diameter", within a short time the drums will be too thin (unsafe) and the new shoes/linings will be subject to overheating and brake fade. How To Measure NOTE: For additional information on how to use a drum micrometer see Fundamentals and Basics. - A drum micrometer is used to measure the drum diameter. - The micrometer scale should be initially set to the original (new) thickness of the drum. - The base of the micrometer should be placed in the deepest groove in the drum and held steady while the measuring point is swiveled to find the maximum diameter. - The base and measuring point should be kept at the same depth in the drum. Drum Micrometer Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 3427 - The measurement should be repeated at 3 or more places around the circumference of the drum to determine if the drum is out of round. If the measurements differ by more than 0.004 inches the drum should be resurfaced. NOTE: A drum which is out of round will cause a pedal pulsation to be felt upon braking. - The measurement should also be repeated at various depths of the drum to check for a bellmouth condition. If the measurements differ by more than 0.010 inches the drum should be resurfaced. NOTE: 1 inch = 25.4mm, so if your micrometer measures in inches and the specified thickness on the disc is in millimeters, convert millimeters to inches by dividing the specified number of millimeters by 25.4. Example: Specification on disc is 17.8 mm. Dividing 17.8mm by 25.4mm/in = 17.8/25.4 = 0.70 inches. NOTE: After a brake drum is machined, wipe the braking surface diameter with a cloth soaked in denatured alcohol. WARNING: If one brake drum is machined, the other should also be machined to the same diameter to maintain equal braking forces. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Removal Brake Drum: Service and Repair Brake Drum Removal For additional information see Notes, Warnings, and Hints. Fig 5 Releasing Automatic Adjuster 1. Raise vehicle on hoist or jacks and install jack stands for safety. 2. Remove wheel and tire assembly. 3. Remove axle shaft nuts, washers and cones. Rap axle shaft sharply in center to release cones if they do not readily release. 4. Remove axle shaft. 5. Remove outer hub nut. Straighten lock washer, remove it, remove inner nut and bearing. Carefully remove drum. CAUTION: If there is interference between brake shoes and drum, remove hole cover and using a screwdriver and light piece of metal, release brake shoes. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Removal > Page 3430 Brake Drum: Service and Repair Brake Drum Installation For additional information see Notes, Warnings, and Hints. 1. Position drum on axle housing. 2. Install bearing and inner nut. Adjust bearing. 3. Install locking washer and outer nut. 4. Bend locking washer to secure. 5. Place new gasket on hub and install axle shaft, cones, lock washers and nuts. 6. Install wheel and tire assembly. 7. Remove jack stands and lower vehicle. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Removal > Page 3431 Brake Drum: Service and Repair Brake Drum Refinishing Fig 4 Eleven Inch Drum Maximum Diameter Identification NOTE: All drums will show markings of maximum allowable diameter. - For example: An eleven inch drum will have a marking of MAX. DIA. 11.090 inch. - This marking includes 0.030 inch for allowable drum wear beyond the recommended 0.060 inch of drum refacing. NOTE: Any brake drum sufficiently out of round to cause vehicle vibration or noise while braking, or showing taper should also be machined, removing only enough stock to true up the brake drum. If the braking surface diameter is within specifications: Drums should be cleaned and inspected for cracks, scores, deep grooves, taper, out of round and heat spotting. If drums are cracked or heat spotted, they must be replaced. - Minor scores should be removed with sandpaper. - Grooves and large scores can only be removed by machining with special equipment, as long as the braking surface is within specifications stamped on brake drum outer surface. MEASURING DRUM RUNOUT AND DIAMETER NOTE: Measure the drum runout and diameter with an accurate gauge. Maximum Variation There should be no variation in the drum diameter greater than 0.O9mm (0.004 in.). Maximum Runout Drum runout should not exceed 0.20mm (0.008 in.) out of round. If the drum runout or diameter variation exceed these values the drum should be refaced. Maximum Single Cut For best results in eliminating the irregularities that cause brake roughness and surge, the amount of material removed during a single cut should be limited to 0.127mm (0.005 in.). Final Cut When the entire braking surface has been cleaned a final cut of 0.025mm (0.001 in.) will assure a good drum surface providing the equipment used is capable of giving the precision required for resurfacing brake drums. - Deeper cuts are permissible for the sole purpose of removing deep score marks. CAUTION: Do not reface more than 1.52mm (0.60 in.) over the standard drum diameter. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Brake Drum Removal > Page 3432 NOTE: If one brake drum is machined, the other should also be machined to the same diameter to maintain equal braking forces. After a brake drum is machined: Wipe the braking surface diameter with a cloth soaked in denatured alcohol. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation Brake Shoe: Service and Repair Brake Shoe Removal and Installation Removal For additional information see Notes, Warnings, and Hints. Fig. 2 Drum Brake Assembly 1. Unhook adjusting lever return spring from the lever. Remove lever and return spring from lever pivot pin. Unhook adjuster lever from adjuster cable assembly. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 3437 Fig 6 Removing Or Installing Shoe To Shoe Spring (Rear) Fig 7 Removing Or Installing Shoe Hold-down Springs (Rear) 2. Using brake spring pliers unhook upper shoe-to-shoe spring. Unhook and remove shoe holddown springs. 3. Disconnect parking brake cable from parking brake lever. Fig 8 Removing Or Installing Shoe Assembly (Rear) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 3438 4. Remove shoes with lower shoe-to-shoe spring and star wheel as an assembly. Installation For additional information see Notes, Warnings, and Hints. Fig 3 Support Plate And Guide Pads NOTE: Pivot screw and adjusting nut have left hand threads on left brake assemblies (brakes on left side of the vehicle) and right hand threads on right hand assemblies (brakes on right side of the vehicle). 1. Lubricate and assemble star wheel assembly. Lubricate guide pads on support plates with MOPAR Multi-Purpose Lubricant Part Number 4318063, or equivalent. Fig 8 Removing Or Installing Shoe Assembly (Rear) 2. Assemble star wheel, lower shoe-to-shoe spring and primary and secondary shoe and position of support plate. 3. Connect parking brake cable to parking brake lever. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 3439 Fig 7 Removing Or Installing Shoe Hold-down Springs (Rear) 4. Install and hook hold-down springs. Fig 6 Removing Or Installing Shoe To Shoe Spring (Rear) 5. Using brake spring pliers replace upper shoe-to-shoe spring. 5. Position adjuster lever return spring on pivot (blue springs on left brakes and white springs on right). 6. Install adjuster lever. Route adjuster cable and connector to adjuster. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Brake Shoe Removal and Installation > Page 3440 Brake Shoe: Service and Repair Cleaning and Inspection For additional information see Notes, Warnings, and Hints. Fig. 6 Release type brake adjuster 1. Remove rear plug from brake adjusting access hole. 2. Insert a thin screwdriver into brake adjusting hole and hold adjusting lever away from notches of adjusting screw. 3. Insert Tool C-3784 or equivalent into brake adjusting hole and engage notches of brake adjusting screw. Release brake by prying down with adjusting tool. 4. Remove rear wheel and clips from wheel studs that holds drum on axle. Discard clips. Remove drums. 5. Inspect brake lining for wear, shoe alignment, or contamination from grease or brake fluid. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder Bleeder Bolt 95 in.lb Rear Wheel Cylinder Mounting Bolt 15 in.lb Wheel Cylinder Flex Hose 25 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Page 3444 Fig 2 Rear Wheel Cylinder 11 And 12 Inch Brakes Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Page 3445 Wheel Cylinder: Description and Operation Fig 2 Rear Wheel Cylinder 11 And 12 Inch Brakes Fig 1 Wheel Cylinder Installation The piston boots are of the press-on type and prevent moisture from entering the wheel cylinder. To perform service operations or inspections of the wheel cylinder , it will be necessary to remove the cylinders from the support plate and disassemble on the bench. CAUTION: Wheel cylinder with cup expanders MUST have cup expanders after any service procedures (reconditioning or replacement). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal Wheel Cylinder: Service and Repair Wheel Cylinder Removal For additional information see Notes, Warnings and Hints. Fig 1 Brake Tube Disconnected 1. Remove brake shoes. - Replace shoes if soaked with grease or brake fluid). 2. Disconnect brake tube from wheel cylinder. Fig 2 Removing Or Installing Wheel Cylinder 3. Remove wheel cylinder attaching bolts, then pull wheel cylinder assembly out of support plate. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 3448 Wheel Cylinder: Service and Repair Wheel Cylinder Installation For additional information see Notes, Warnings and Hints. Brake Shoe Contact Pads On Backing (Support) Plate 1. Apply RTV sealant around wheel cylinder mounting surface. Fig 1 Wheel Cylinder Installation Fig 2 Removing Or Installing Wheel Cylinder Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 3449 Fig 1 Brake Tube Disconnected 2. Slide wheel cylinder into position on support plate. 3. Install mounting screws and tighten as specified. 4. Connect brake tube to wheel cylinder. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 3450 Wheel Cylinder: Service and Repair Cleaning and Inspection Fig 2 Rear Wheel Cylinder 11 And 12 Inch Brakes 1. With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. 2. Block brake pedal in stroke position. 3. Visually check the boots for cuts, tears, or heat cracks. - If any of these conditions exist, the wheel cylinders should be completely cleaned, inspected and new parts installed. NOTE: A slight amount of fluid on the boot may not be a leak, but may be preservative fluid used at assembly. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 3451 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul For additional information see Notes, Warnings and Hints. Fig 2 Rear Wheel Cylinder 11 And 12 Inch Brakes NOTE: To perform service operations or inspections of the wheel cylinders, it will be necessary to remove the cylinders from the support plate and disassemble on the bench. CAUTION: Wheel cylinders with cup expanders MUST have cup expanders after any service procedures (reconditioning or replacement). DISASSEMBLING WHEEL CYLINDERS 1. Using a suitable tool, pry boots away from cylinders and remove. 2. Remove push rods. 3. Press In on one piston to force out other piston, cup, spring -- with cup expanders -- cup and piston. 4. Wash wheel cylinder, pistons, and spring in clean brake fluid or alcohol. - Clean thoroughly and blow dry with compressed air. CAUTION: Do not use a rag as lint from the rag will adhere to bore surfaces. INSPECTION Inspect cylinder bore and piston for scoring and pitting. Wheel cylinder bores and pistons that are badly scored or pitted should be replaced. - Cylinder walls that have light scratches, or show signs of corrosion, can usually be cleaned with crocus cloth, using a circular motion. - Black stains on the cylinder walls are caused by piston cups and will not impair operation of cylinder. ASSEMBLING WHEEL CYLINDERS NOTES: - Before assembling the pistons and new cups in the wheel cylinders, dip them in clean brake fluid. - If the boots are deteriorated, cracked or do not fit tightly on the push rods or the cylinder casting, install new boots. 1. Coat cylinder bore with clean brake fluid. 2. Install expansion spring with cup expanders in cylinder. 3. Install cups in each end of cylinder with open end of cups facing each other. 4. Install piston in each end of cylinder having the flat face of each piston contacting the flat face of each cup, already installed. 5. Install a boot over each end of cylinder and press over ends until boot is seated against cylinder shoulder. Use care not to damage boot. 5. Lubricate spherical end of each push rod with brake fluid and insert each into boot. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding Brake Bleeding: Service and Repair About Brake System Bleeding WHEN BLEEDING BRAKES REMEMBER... - Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender covers to protect the vehicle's finish and electrical system. - Always flush and bleed the brake hydraulic sys. when servicing the brakes, because: Brake fluid absorbs moisture from the air, after 3-4 years of service the water content of the brake fluid may be as high as 6-7%. This significantly reduces the boiling point of the brake fluid which may result in a soft pedal or brake failure during prolonged or severe braking. Corrosion deposits and other contaminants gradually build up inside of the brake hydraulic sys. Check the bottom of the master-cylinder reservoir for a build up of fine black silt. If any is present the brake fluid should be flushed. - Never reuse brake fluid that has been drained from the brake system. DOT 3,4 or DOT 5 As a general rule DOT 5 brake fluid should not be used in vehicles recommending DOT 3 or 4 type fluid. DOT 5 brake fluid is silicone based. DOT 3 (standard) and DOT 4 (heavy-duty) are glycol-based. DOT 5 can be distinguished from conventional brake fluids by its purple color (which comes from a dye). DOT 5 silicone brake fluid won't mix with glycol-based brake fluid (creating concern over sludging if all old fluid isn't removed when a system is refilled with silicone). Silicone does not absorb moisture. DOT 5 brake fluid does not become contaminated with moisture over time as conventional DOT 3 and 4 brake fluids do. Silicone is also chemically inert, nontoxic and won't damage paint like conventional brake fluid. It also has a higher boiling point. Because of this, it is often marketed as a premium "lifetime" brake fluid. It is often used to preserve brake systems in antique vehicles and those that sit for long periods of time between use. Silicone also has slightly different physical properties and compressibility, making it unsuitable for ABS systems calibrated to work with DOT 3 or 4 brake fluid. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 3457 Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures Fig 2 Extending Valve Stem NOTE: All vehicles are equipped with a pressure hold-off valve. The valve is located (in the combination valve) on the left frame rail. The hold off valve balances front and rear braking force to improve braking and steering control on icy surfaces. The valve shuts off the flow of brake fluid between 3 and 135 PSI. Because the valve shuts off flow in this pressure range the valve must be held open manually -- using tool C-4121 or equivalent -- when pressure bleeding the system. CAUTION: Under no circumstances should a rigid clamp, wedge or block be used to depress the valve stem. This could cause an internal valve failure resulting in complete loss of front brakes. 1. Clean all dirt and foreign material from the cover of the master cylinder to prevent dirt from falling into the master cylinder reservoir when the cover is removed. 2. Install metering valve hands off tool, part No. C-4121 to valve stem of metering valve. NOTE: Complete bleeding of dual master cylinder is important before performing this procedure! 3. Starting with RWAL hydraulic valve, clean all dirt from the bleeder valve. 4. Place bleeder hose on the bleeder valve and insert the other end of the bleeder hose into a clear jar half filled with clean brake fluid. This will permit the observation of air bubbles as they are being expelled from the hydraulic system and also prevent air from being drawn back into the system. 5. Continue this bleeding with: a. The right rear wheel b. Then left rear wheel c. Next, bleed the right front and d. Finish with the left front wheel 6. Repeat this bleeding procedure if there is any indication of air remaining in the hydraulic system: - Spongy brake pedal - Warning light ON CAUTION: The pressure release valve is in its innermost position when there is no pressure present. No attempt should be made to further depress the valve stem. NOTE: If diagnosis determines that master cylinder alone is cause of trouble, it can be replaced without bleeding the hydraulic system provided the replacement cylinder is completely bled before installation. After brake tubes are connected have helper apply force to pedal while both tube nuts are cracked to release any air and then retightened. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > About Brake System Bleeding > Page 3458 Brake Bleeding: Service and Repair Pressure Bleeding (Preferred Procedure) Fig 2 Extending Valve Stem NOTE: All vehicles are equipped with a pressure hold-off valve. The valve is located (in the combination valve) on the left frame rail. The hold off valve balances front and rear braking force to improve braking and steering control on icy surfaces. The valve shuts off the flow of brake fluid between 3 and 135 PSI. Because the valve shuts off flow in this pressure range the valve must be held open manually -- using tool C-4121 or equivalent -- when pressure bleeding the system. CAUTION: Under no circumstances should a rigid clamp, wedge or block be used to depress the valve stem. This could cause an internal valve failure resulting in complete loss of front brakes. 1. Clean all dirt and foreign material from the cover of the master cylinder to prevent dirt from falling into the master cylinder reservoir when the cover is removed. 2. Install metering valve hands off tool, part No. C-4121 to valve stem of metering valve. NOTE: Complete bleeding of dual master cylinder is important before performing this procedure! 3. Starting with RWAL hydraulic valve, clean all dirt from the bleeder valve. 4. Place bleeder hose on the bleeder valve and insert the other end of the bleeder hose into a clear jar half filled with clean brake fluid. This will permit the observation of air bubbles as they are being expelled from the hydraulic system and also prevent air from being drawn back into the system. 4. Continue this bleeding with: a. The left rear wheel. b. Next, bleed the right front. c. Finish with the left front wheel. 6. Repeat this bleeding procedure if there is any indication of air remaining in the hydraulic system: - Spongy brake pedal - Warning light ON CAUTION: The pressure release valve is in its innermost position when there is no pressure present. No attempt should be made to further depress the valve stem. NOTE: If diagnosis determines that master cylinder alone is cause of trouble, it can be replaced without bleeding the hydraulic system provided the replacement cylinder is completely bled before installation. After brake tubes are connected have helper apply force to pedal while both tube nuts are cracked to release any air and then retightened. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Caliper Adapter To Steering Knuckle 110 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Testing and Inspection > With Caliper On Vehicle Brake Caliper: Testing and Inspection With Caliper On Vehicle Fig 9 Caliper Assembly Check for piston seal leaks (evident by brake fluid in and around boot area and inboard lining) and for any ruptures of piston dust boot. If boot is damaged, or fluid is evident, it will be necessary to disassemble caliper assembly and install a new seal, boot, (and piston if damaged or corroded). Check the mating surfaces of the abutments on the caliper and adaptor. If corroded or rusty, clean surfaces with wire brush. Inspect braking surfaces of disc. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Testing and Inspection > With Caliper On Vehicle > Page 3464 Brake Caliper: Testing and Inspection With Caliper Removed WITH CALIPER ON VEHICLE Check for piston seal leaks (brake fluid in and around boot area and inboard lining) and for any ruptures of piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper assembly and install a new seal and boot, (and piston if corroded or scored). Check the mating surfaces of the abutments on the caliper and adapter. If corroded or rusty, clean surfaces with wire brush. Inspect braking surfaces of disc. Check dust boots for punctures or tears. If punctures or tears are evident, new boots should be installed upon reassembly.. WITH CALIPER REMOVED Cleaning Clean all parts using alcohol or a suitable solvent and blow dry, using compressed air. Blow out all drilled passages and bores. NOTE: Black stains on the bore walls are caused by piston seals and will do no harm. Inspect the piston bore for scoring or pitting Bores that show light scratches or corrosion, can usually be cleared with crocus cloth. - Bores that have deep scratches or scoring should be honed, providing the diameter of the bore is not increased more than 0.002 inch. - If the bore does not clean up within this specification, a new caliper housing should be installed. Install a new piston if the old one is pitted or scored. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation Brake Caliper: Service and Repair Removal and Installation Removal For additional information see Fundamentals and Basics. See: Fundamentals and Basics Fig 3 Adaptor And Caliper Machined "Ways" And Caliper Retention NOTE: It may be necessary to remove fluid to put in new linings as fluid is pushed back into the master cylinder. NOTE: It is necessary to remove the caliper to install a new piston seal and boot. 1. Raise the vehicle on jackstands or hoist. 2. Remove front wheel covers and wheel and tire assemblies. 3. Disconnect flexible brake hose from caliper. If pistons are to be removed from caliper leave brake hose connected to caliper. 4. Plug brake tube to prevent loss of fluid, or prop brake pedal to any position below first inch of travel. 5. Disconnect hose from caliper. 6. Remove retaining screw, retaining clip (and anti-rattle spring) that attach caliper to adaptor. Fig 6 Removing Or Installing Caliper 7. Carefully slide caliper out and away from disc and adaptor. Installation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3467 For additional information see Fundamentals and Basics. See: Fundamentals and Basics NOTE: Examine linings for wear, damage or fluid contamination if linings are satisfactory they may be reused. - If not usable both front brakes must be relined with new lining. - If old linings are to be reused, be sure linings are installed in their original position. 1. Slide new outboard shoe and lining assembly in recess of caliper. CAUTION: No free play between brake shoe flanges and caliper fingers should exist (which might cause brake shoe rattle). Fig. 7 Bending Outboard Pad Retaining Flange Fig 12 Attaching Shoe To Caliper Fingers With C-clamp NOTE: If free play is evident by vertical shoe movement after installation, remove shoe from caliper and bend flanges to create slight interference fit to eliminate all vertical free play when shoe is installed. Install shoe after above modification, if necessary, by snapping shoe into place with fingers or with light "C" clamp, protect new lining from damage or contamination by using old pads over new lining and across caliper fingers. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3468 Fig 8 Removing Or Installing Shoe 2. Position inboard shoe in position on adaptor with shoe "flanges" in the adaptor "ways". 3. Slowly slide caliper assembly into position in adaptor and over disc. - Align caliper on machined ways of adaptor. - Be careful not to pull the dust boot from its groove as the piston and boot slide over the inboard shoe. 4. Install anti-rattle springs and retaining clips and torque retaining screws to 200 inch-pounds. Fig 3 Adaptor And Caliper Machined "Ways" And Caliper Retention NOTE: The inboard shoe anti-rattle spring must always be installed on top of the retainer spring plate. 5. With bleeder screw open, allow caliper to "Gravity" fill with brake fluid, then close bleeder screw. (Be sure all air bubbles have escaped; replenish brake fluid in master cylinder. Bleed brakes. 6. Pump brake pedal several times until a firm pedal has been obtained. 7. After bleeding caliper, check for fluid tightness under maximum pedal pressures. (Recheck master cylinder reservoir level). 8. Install wheel and tire assembly. 9. Remove jackstands or lower hoist. 10. Road test vehicle and make several stops to wear off any foreign material on the brakes and to seat the linings. - The vehicle may pull to one side or the other if this is not done. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3469 Brake Caliper: Service and Repair Disassembly and Assembly Disassembly Fig 3 Adaptor And Caliper Machined "Ways" And Caliper Retention 1. Raise vehicle, remove wheel and tire assemblies. 2. Remove retaining screw, retaining clip (and anti-rattle spring) that attach caliper to adaptor. Fig 6 Removing Or Installing Caliper 3. Carefully slide caliper out and away from disc and adaptor. 4. Remove outboard shoe and lining assembly from caliper. 5. To remove piston, support caliper assembly on upper control arms on shop towels to absorb any hydraulic fluid loss. a. Carefully depress brake pedal to hydraulically push piston out of bore (brake pedal will fall away when piston has passed bore opening) b. Prop brake pedal to any position below the first inch of pedal travel to prevent loss of brake fluid. (If both front caliper pistons are to be removed, disconnect flexible brake line at frame bracket after removing first piston. Plug brake tube to remove piston from opposite caliper.) CAUTION: Under no condition should air pressure be used to remove piston from bore. Personal injury could result from such practice. 6. Disconnect brake flexible hose from the caliper. 7. Mount caliper assembly in a vise equipped with protector jaws. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3470 CAUTION: Excessive vise pressure will cause bore distortion and binding of piston. 8. Remove dust boot using suitable tool. Fig. 11 Piston Seal Removal 9. Using a small, pointed, wooden or plastic stick, work piston seal out of its groove in piston bore. Discard old seal. CAUTION: Do not use a screwdriver or other metal tool for this operation, because of possibility of scratching piston bore or burring edges of seal groove. Assembly Fig. 12 Piston Seal Installation 1. Clamp caliper in vise (with protector jaws). CAUTION: Excessive vise pressure will cause bore distortion and binding of piston. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3471 2. Dip new piston seal in clean brake fluid and install in groove in bore. Seal should be positioned at one area in groove and gently worked around the groove, using fingers, until properly seated. Make sure that fingers are clean. Never use an old piston seal. (Be sure seal is not twisted or rolled). 3. Coat new piston boot with clean brake fluid leaving a generous amount inside of boot. 4. Position dust boot over piston. Fig 16 Installing Piston Through Boot 5. Install piston into bore pushing it past the piston seal until the piston bottoms in the bore. Fig. 13 Dust Boot Installation 6. Position the dust boot in the counterbore. Using a hammer and Tool C-4690 with handle C-4171, or equivalent, drive the boot onto the counterbore. CAUTION: Force must be applied uniformly to avoid cocking. 7. Install brake hose to caliper using new seal washers. NOTE: Before installing caliper assembly on vehicle, inspect braking disc runout and thickness. Cleaning, Inspecting & Honing Caliper Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Removal and Installation > Page 3472 Fig 14 Honing Piston Bore Clean all parts using alcohol or a suitable solvent and blow dry, using compressed air. Blow out all drilled passages and bores. NOTE: Whenever a caliper has been disassembled, a new boot and seal must be installed at reassembly. Inspect the piston bore for scoring or pitting. Install a new piston if it is pitted, scored or the plating is severely worn. - Bores that show light scratches or corrosion, can usually be cleared with crocus cloth. - Bores that have deep scratches or scoring should be honed, using Tool C-4095, or equivalent, providing the diameter of the bore is not increased more than 0.002 inch (0.050mm). - If the bore does not clean up within this specification, a new caliper housing should be installed. NOTE: Black stains on the piston are caused by the piston seal and will do no harm. When using Hone C-4095 or equivalent, coat the stones and bore with brake fluid. After honing the bore, carefully clean the seal and boot grooves with stiff non-metallic rotary brush. CAUTION: Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing the caliper with brake fluid; wipe dry with a clean, lintless cloth and then clean a second time in the same manner or until clean cloth shows no signs of discoloration. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes Brake Caliper: Fundamentals and Basics Removal Notes When Removing the Caliper, Remember... - Prior to removing the calipers, remove/siphon brake fluid from master-cylinder until the reservoir is only 1/3 full. - Brake fluid will remove paint and damage electrical connections. Use a drip pan and fender covers to protect the vehicle's finish and electrical system. - Always replace all brake linings on an axle. Never replace only one wheel. Unequal lining thickness between wheels on the same axle will result in a strong steering pull when the brakes are applied. - Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. - When forcing the piston back into the caliper, open the bleeder valve first. Corrosion and other deposits accumulate inside of the caliper. If the bleeder valve is not opened when the piston is forced back into the caliper, these deposits will be forced back through the brake lines and into the master-cylinder. - When pushing the pistons back into the caliper with the bleeder screw open, a stream of brake fluid will be expelled from the bleeder screw for 2-3 feet. Use a drip pan and be careful not to "shoot" brake fluid onto the vehicle's finish. A cleaner method is to use a piece of clear plastic hose and a glass or plastic jar to catch the expelled fluid. - Upon removal, Do Not allow the calipers to hang by the flexible brake hoses. The brake hoses can be damaged easily by this practice. These hoses are double walled, damage to the interior pressure hose will not be visible. - Do not depress the brake pedal with either caliper removed from the rotor. The caliper pistons will be inadvertently expelled from the caliper. If this occurs rebuild or replace the caliper, do not attempt to insert the piston back into the caliper. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 3475 Brake Caliper: Fundamentals and Basics Installation Notes WHEN INSTALLING CALIPERS AND PADS, REMEMBER... - Clean and lubricate caliper slide joint/pins with high temperature silicone grease: Unlike drum brakes, disc brakes do not utilize a spring to withdraw the pads/linings when the brake pedal is released. Disc brakes rely on the elasticity of the piston seals, and the unrestricted movement of the caliper slide assemblies to release the brakes. If the slide joints/pins are not cleaned and lubricated properly the disc brake linings will drag upon the release of the brake pedal. This will result in overheated brakes and premature brake wear. Disc Brake Mechanical Force Diagram NOTE: Floating calipers require free and unrestricted movement on the caliper mounting. Floating or sliding calipers have pistons only on one side of the rotor. The first part of the piston's travel forces the inner pad against the rotor, then further travel forces the movable part of the caliper to pull the outer pad against the rotor. High temperature silicone lubricant must be used. Low temperature grease can melt and contaminate the pads and rotors, or can bake into a very hard substance which binds the slides. Petroleum based grease can cause the slide boots to soften and swell. - Work on one side at a time. If you forget how to reassemble the parts you can always use the other side as a model. Anti-squeal Coating - Apply an anti-squeal coating to the back side of the pads/linings. This coatings acts as an insulator to dampen high frequency vibrations that are generated during normal braking. These compounds are highly effective in preventing brake squeal. - Many professional repair shops recommend always rebuilding or replacing the calipers when replacing the brake linings, because: When the pistons are forced back into the calipers, the piston seals are dragged across any corrosion or abrasives that may be deposited on the inside of the caliper. Damage to the seals may not be initially evident. As the new brake linings begin to wear, the piston is gradually withdrawn from the caliper. This results in the piston seals again being dragged across the layer of corrosion and deposits. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Fundamentals and Basics > Removal Notes > Page 3476 Calipers which are not rebuilt or replaced have a higher probability of sticking or leaking. - Check to ensure the bleeder screw is not frozen prior to reinstalling caliper. Freeing a stuck bleeder screw is much easier with the caliper removed from the vehicle. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Testing and Inspection Brake Fluid: Testing and Inspection NOTE: Swollen rubber parts indicate the presence of petroleum in the brake fluid. To confirm that contamination exists, make the following test: Place a small amount of the drained brake fluid into a small clear glass bottle. Separation of the fluid into distinct layers will indicate mineral oil content. If there is any question of mineral oil content, drain system, flush thoroughly and replace all rubber parts. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Testing and Inspection > Page 3480 Brake Fluid: Service and Repair Aluminum Master Cylinder NOTES: - With disc brakes, fluid level can be expected to fall as the brake pads wear. - Check master cylinder fluid level twice annually. - Master cylinder reservoirs are marked with the words "fill to bottom of rings". 1. Wipe caps and reservoir clean to prevent dirt and foreign matter from dropping into the reservoir. 2. Remove the caps to check the level. - On aluminum master cylinder add DOT 3 fluid to bring the level to the bottom of the primary split ring. - On the cast iron master cylinder, add DOT 3 fluid to bring the level to within a 1/4 inch of the top of reservoir. CAUTION: Use fluid other than DOT 3 that may have a lower boiling point -- such as fluid identified as 7OR1 or unidentified as to specification -- could result in brake failure during long, hard braking. CAUTION: Do not use fluid which has been stored in an unsealed container. Brake fluid stored in this manner will absorb moisture which could result in brake failure during long, hard braking. CAUTION: Use of petroleum based fluids will result in seal damage. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions Brake Fluid Pressure Sensor/Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3485 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3486 Brake Fluid Pressure Sensor/Switch: Electrical Diagrams Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3487 Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3488 Fig. 20 Ignition Switch With Tilt Wheel Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Page 3489 Brake Fluid Pressure Sensor/Switch: Testing and Inspection Brake Warning Switch Testing 1. Raise the car on a hoist and open a wheel cylinder bleeder while a helper depresses the brake pedal and observes the warning light. 2. If the light fails to light, inspect for a burned out bulb, disconnected socket, or a broken or disconnected wire at the switch. 3. If the bulb is not burned out and the wire continuity is uninterrupted, check the service brake warning switch operation with a test lamp between the switch terminal and a voltage source. 4. If light still fails to light, disconnect the brake tubes from the valve assembly and install a new valve assembly. 5. If a new valve is installed, bleed the system. CAUTIONS: - Do not disassemble valve to reset the piston. - The warning switch is not serviced separately. Do not remove the switch or attempt to repair. NOTE: After repairing and bleeding the brake system, applying the brakes with moderate force will hydraulically recenter the piston and automatically turn off the warning light. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications Brake Hose/Line: Specifications Front wheel brake hose mounting bolt .......................................................................................................................................................... 24 ft lb (32 Nm) Flexible Brake Hose to brake line tubes (all) ............................................................................................................................... 80-150 in lb (9.8-18.4 Nm) Wheel Cylinder Flex Hose ............................................................................................ ................................................................................ 25 ft lb (34 Nm) Brake Line Tube Nuts 3/8" or 7/16" ......................................................................................................................................... ......................... 116-175 in lb (12.9-19.7 Nm) 1/2" or 9/16" ................................................................ .................................................................................................. 140-200 in lb (15.0-22.5 Nm) Bottom attaching bolts ..................................................................................................................................... ............................... 120 ft lb (162 Nm) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 3493 Brake Hose/Line: Testing and Inspection NOTE: Flexible rubber hose is used at both front brakes and at a rear axle junction block. Inspection of brake hoses should be performed whenever the brake system is serviced and every 7,500 miles or 12 months, whichever comes first (every engine oil change). Inspect flexible hydraulic brake hoses for: Severe surface cracking - Scuffing - Worn spots If the fabric casing of the rubber hose is exposed due to cracks or abrasions in the rubber hose cover, the hose should be replaced immediately! Eventual deterioration of the hose can take place with possible burst failure. CAUTION: Faulty installation can cause twisting, and wheel, tire or chassis interference. Inspect steel brake tubing for: Evidence of physical damage that may restrict fluid flow. - Heavily corroded tubing may eventually develop a leak. In either case, the tubing should be replaced. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 3494 Brake Hose/Line: Service and Repair NOTE: Always use factory recommended hose to insure quality, correct length and superior fatigue life. CAUTION: Care should be taken to make sure that the tube and hose mating surfaces are clean and free from nicks and burrs. CAUTION: Right and left brake hoses are not interchangeable. NOTE: Use new, copper seal washers. All connections should be properly made and torqued. 1. The flexible hydraulic brake hose should always be installed on the vehicle by first tightening the block end of the hose onto caliper, or rear axle housing tee. 2. The intermediate bracket should then be bolted to the upper control arm. 3. The hose bracket is then attached to the side rail. 4. Finally, the tube is attached to the hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Application and ID Brake Proportioning/Combination Valve: Application and ID Fig. 23 Type 1, Combination Valve Fig 2 Brake Warning Switch / Hold Off Valve (Cut Away View) All models are equipped with a single hydraulic system control valve mounted on the frame rail below the master cylinder. There are two types of control valves available on most models: On some models a brake warning switch is combined with a hold-off and proportioning valve assembly. Hold-off cut in pressure ...................................................................................................... ........................................................................ 117 PSI Split Point (PSI)/Slope .................................. ............................................................................................................................................ 300/0.27 ID tag color .......................................................................................................................................... .......................................................... White - On other models a brake warning switch and hold-off valve assembly are combined -- without a proportioning valve. ID tag color .......................................................................................................... .......................................................................................... Black Hold-off cut in pressure ................... ........................................................................................................................................................... 117 PSI During any service procedures identify valve assemblies by part number as well as hold off/cut in (PSI) and split point (PSI). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Brake Warning Switch Description Brake Proportioning/Combination Valve: Description and Operation Brake Warning Switch Description Fig. 23 Type 1, Combination Valve Fig 2 Brake Warning Switch / Hold Off Valve (Cut Away View) NOTE: This valve is part of a combination valve. See Application and ID. NOTE: The brake warning light is lit only when the parking brake is applied with the ignition key turned "ON" or when one of the two service brake systems has failed. The hydraulic system brake warning switch warns the vehicle operator that one of the hydraulic systems has failed. A failure in one part of the brake system does not result in failure of the entire hydraulic brake system. - As an example, failure of the rear brake system will leave the front brake system still operative. If a pressure loss occurs in one side of the dual brake system, the difference in pressure causes the piston to move to the failed side and latch in that position. This will cause the brake system warning light to come on and stay on after the pedal is released. - After the system is repaired and bled, a moderate application of the brake pedal will hydraulically recenter the piston and automatically turn off the warning light. CAUTION: Do not disassemble valve to reset the piston. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Brake Warning Switch Description > Page 3500 Brake Proportioning/Combination Valve: Description and Operation Hold-Off Valve Fig. 23 Type 1, Combination Valve Fig 2 Brake Warning Switch / Hold Off Valve (Cut Away View) NOTE: Some vehicles incorporate a hold-off valve, usually in combination with the brake warning switch. This valve is part of a combination valve. See Application and ID. PURPOSE Hold-off valves are used because of different braking characteristics between disc and drum brakes. This valve holds off hydraulic pressure to the front disc brakes to a given pressure range to allow the rear drum brake shoes to overcome the return springs and begin to contact drums. - With disc brakes, brake application is immediate and braking response is directly proportional to pedal effort. - Drum brake response occurs after piston travel, return spring stretch, and shoe contact with the drum. After contact self energizing tends to multiply pedal effort. - This action helps prevent locking of the front brakes on icy surfaces under light braking conditions. - This valve has no effect on front brake pressure during hard stopping. OPERATION The hold-off valve section of the combination valve holds off pressure to the front disc brakes to allow the rear drum brake shoes to overcome the return springs and begin to contact the drums. This valve keeps the output pressure to the front brakes in the 3 to 30 PSI range until the hold-off pressure in the hold off valve reaches (117 PSI) at this point the valve allows full output pressure to reach the front brakes. - This helps to prevent the front brakes from locking under light pedal application when driving on icy surfaces. NOTE: The hold off valve has no effect on front brake pressure during hard stops. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Brake Warning Switch Description > Page 3501 Brake Proportioning/Combination Valve: Description and Operation Proportioning Valve Fig. 23 Type 1, Combination Valve Fig 2 Brake Warning Switch / Hold Off Valve (Cut Away View) NOTE: This valve is part of a combination valve. See Application and ID. The proportioning valve section transmits full input pressure to the rear brakes up to a certain point, called the split point. Beyond that point it reduces the amount of pressure increase to the rear brakes according to a certain ratio. On light pedal applications, approximately equal brake pressure will be transmitted to the front and rear brakes. - At higher pressures, the pressure transmitted to the rear brakes will be lower than to the front brakes to prevent premature rear wheel lock-up and skid. If hydraulic pressure is lost in the front brake system, rear brake system hydraulic pressure moves the brake warning switch piston and opens a bypass in the proportioning unit allowing full rear brake hydraulic pressure. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > Hold Off Valve Inspection Brake Proportioning/Combination Valve: Testing and Inspection Hold Off Valve Inspection Normal Operation A visual check will show that the valve stem extends slightly when the brakes are applied and retracts when the brakes are released. In Case of Malfunction In case of a hold-off valve malfunction, remove the valve and install a new combination valve assembly. CAUTION: Follow correct procedure to bleed the hydraulic system on vehicles equipped with hold-off valves. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Testing and Inspection > Hold Off Valve Inspection > Page 3504 Brake Proportioning/Combination Valve: Testing and Inspection Proportioning Valve Testing Fig 3 Testing Proportioning Section Of Combination Valve Symptom Premature rear wheel slide on brake application could be an indication that the fluid pressure to the rear brakes is above the reduction ratio for the rear line pressure and that a malfunction has occurred in the proportioning valve unit. If this symptom is experienced the proportioning valve should be tested. NOTE: During testing, leave front brake lines connected to the valve. Proportioning Valve Unit Test 1. Install one gauge and "T" of set C-4007A or equivalent, between brake line from master cylinder secondary port and brake valve assembly. 2. Install a second gauge to the rear brake outlet port between the valve assembly and the rear brake line. - An adaptor tube, made up locally of a 9/16 x 18 tube nut, short piece of brake tube and 3/8 x 24 tube nut will be required to connect the hose to the valve. 3. Bleed the rear brake system. 4. Have a helper exert and hold pressure on the brake pedal to get a reading on the valve inlet gauge and check the reading on the outlet gauge. - If the inlet and outlet pressures do not agree with the values on the following chart, replace the valve. 5. Valve assemblies for all models are shipped in the front failed position to improve bleeding. - When installing a new valve, bleed the rear brakes first. - After bleeding both front and rear systems, applying the brakes with moderate force will hydraulically reset the switch and turn off the warning light. Hold-off cut in pressure ....................................................................................................................... ...................................................................... 117 PSI ID tag color .......................................................................................................................................... .......................................................................... Black Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Master Cylinder to Booster ............................................................................................................................................................ 170-230 in lb (22.5 Nm) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 3508 Brake Master Cylinder: Application and ID Fig 1 Aluminum Master Cylinder (Cut Away View) Aluminum Master Cylinder (Black Plastic Reservoir) Fig 1 Cast Iron Master Cylinder Cast Iron Master Cylinder (Cast Iron Reservoir) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Aluminum Master Cylinder Brake Master Cylinder: Description and Operation Aluminum Master Cylinder Fig 1 Aluminum Master Cylinder (Cut Away View) The body of the two piece master cylinder, is made of aluminum and the reservoir is made of glass reinforced nylon. The two compartments of the reservoir are interconnected to permit equalization of the fluid level. However a sufficient quantity of fluid is retained in the reservoir of the unaffected system to permit operation of that half of the master cylinder even if the other half of the reservoir is drained due to a hydraulic leak. The forward most outlet tube from the master cylinder is connected to the hydraulic system control valve and then to the rear brakes. this system is referred to as the secondary. The rear most outlet tube from the master cylinder is connected to the control valve and the front brakes. this system is referred to as primary. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Aluminum Master Cylinder > Page 3511 Brake Master Cylinder: Description and Operation Cast Iron Master Cylinder Fig 1 Cast Iron Master Cylinder Fig 2 Cast Iron Master Cylinder (Top View) The cast iron master cylinder is a venting type with reservoirs cast integrally. It consists of a primary and secondary piston (in tandem) with outlet tubes from the master cylinder connected to the hydraulic system warning switch valve and then from the primary switch port to the front bakes and from the secondary port to the rear brakes. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Page 3512 Brake Master Cylinder: Testing and Inspection INSPECTION Inspect for Leakage NOTE: The master-cylinder should be cleaned thoroughly prior to inspection (several days preferably). Spilled brake fluid can be easily confused with leakage. Piston Seals Leakage around the piston seals will seep out from the end of the cylinder and leak down the outside of the brake booster. - Inspect for signs of seepage or bubbled paint on the brake booster. - If any leakage is detected the master-cylinder should be replaced or overhauled Brake Line Fittings While someone is applying pressure to the brake pedal, inspect the brake line fittings on the master-cylinder for leakage. - If the fittings are leaking they should be disassembled and inspected. Reservoir to Cylinder Gasket Inspect the gasket for signs of leakage or hardening and cracking. Overhaul or replace the master-cylinder if any leakage is indicated. Inspect for Oil Contamination. - Inspect the rubber gasket on the inside of the master-cylinder lid. If the gasket is swollen or bloated, the brake fluid is contaminated with oil. - Siphon or scoop a small amount of brake fluid out of the master-cylinder and place into a styrofoam cup filled 2/3 of the way with water. Brake fluid will mix with the water while oil contaminants will float on the surface and dissolve the styrofoam. NOTE: If any oil contamination is present ALL brake components containing rubber seals will need to be replaced or overhauled. This includes the master-cylinder, both front calipers, both rear wheel cylinders, and all flexible brake hoses. Verify Hold-Down Bolts Are Tight - While someone is applying and releasing pressure to the brake pedal, verify the the master-cylinder is tightly secured to the brake booster. Retighten hold-down bolts if necessary. Functional Checks WARNING: Always bleed the entire brake system and verify the rear brakes are properly adjusted prior to diagnosing a master-cylinder as defective. For additional information on master-cylinder / brake pedal relationship see Fundamentals and Basics. See: Fundamentals and Basics Check Related Systems Check for proper brake booster operation 1. With the engine "OFF", depress and release the brake pedal 4-5 times (this bleeds off the vacuum reserve in the booster). 2. Depress the brake pedal firmly and start the engine. If the pedal goes down slightly the brake booster is assisting in brake operation. If the pedal does not go down slightly the brake booster is not assisting in brake operation and should be diagnosed for problems. - Check and adjust rear brakes. - Check all brake lines and brake assemblies for leakage. Repair all deficiencies with related systems prior to diagnosing the master-cylinder as defective. Check Brake Pedal Travel (Non-Antilock Brake Systems Only) Fully depress the brake pedal and check for the following: The pedal should have a 75% reserve. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Page 3513 Pedal Reserve Checks - The pedal should be firm and not leak down. Prior to replacing a master-cylinder for poor pedal travel or feel verify the following: There were no problems with any of the related systems. - The entire brake system has been bled. - Rear brakes are properly adjusted. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Page 3514 Brake Master Cylinder: Adjustments Not adjustable. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Brake Master Cylinder: Service and Repair Master Cylinder Bleeding Aluminum Master Cylinder For additional information see Bench Bleeding Notes. See: Fundamentals and Basics Fig 3 Bench Bleeding Master Cylinder NOTE: It is not necessary to bleed the entire hydraulic system after replacing the master cylinder if the master cylinder has been bench bled and refilled prior to installation. 1. Clamp master cylinder in vise and attach bleeding tubes. 2. Fill both reservoirs with approved brake fluid. 3. Using a brass rod or wooden dowel, depress push rod slowly and then allow pistons to return under pressure of springs. 4. Repeat several times until all air bubbles are expelled. 5. Remove bleeding tubes from cylinder, plug outlets and install caps. 6. Remove from vise and install master cylinder on vehicle. Cast Iron Master Cylinder For additional information see Bench Bleeding Notes. See: Fundamentals and Basics Fig 2 Cast Iron Master Cylinder (Top View) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 3517 Fig 3 Cast Iron Master Cylinder (Exploded View) NOTE: Before installing the master cylinder on the vehicle it must be bled on the bench using the following procedure: 1. Clamp master cylinder in vise and attach bleeding tubes. 2. Fill both reservoirs with approved brake fluid. 3. Using a brass rod or wooden dowel, depress push rod slowly and then allow pistons to return under pressure of springs. 4. Repeat several times until all air bubbles are expelled. 5. Remove bleeding tubes from cylinder, plug outlets and install gasket and cover. 6. Install cover clamp. 7. Remove from vise and install master cylinder on vehicle. Pressure Bleeding WITHOUT ABS 1. Clean all dirt and foreign material from the cover of the master cylinder to prevent dirt from falling into the master cylinder reservoir when the cover is removed. NOTE: Using the one-man Bleeder Tank C-3496B (with adaptor C-4578) provides a convenient means for pressurizing the hydraulic system for bleeding. Follow the manufacturers instructions in the use of the bleeder tools. NOTE: Complete bleeding of dual master cylinder is important before performing this procedure! 2. Starting with the right rear wheel, clean all dirt from the bleeder valve. 3. Place bleeder hose on the bleeder valve and insert the other end of the bleeder hose into a clear jar half filled with clean brake fluid. This will permit the observation of air bubbles as they are being expelled from the hydraulic system and also prevent air from being drawn back into the system. 4. Continue this bleeding with: a. The left rear wheel. b. Next, bleed the right front. c. Finish with the left front wheel. 5. Repeat this bleeding procedure if there is any indication of air remaining in the hydraulic system: - Spongy brake pedal - Warning light ON Gravity Bleed: Remove master cylinder reservoir cover and gasket, then fill reservoirs with approved brake fluid. Open disc brake bleeder screws, and allow fluid and air to drain until stream of fluid is free of air. Pedal Bleed: Follow normal procedure of pumping pedal and opening bleeder screws. Do not pump master cylinder dry! NOTE: If diagnosis determines that master cylinder alone is cause of trouble, it can be replaced without bleeding the hydraulic system provided the replacement cylinder is completely bled before installation. After brake tubes are connected have helper apply force to pedal while both tube nuts are cracked to release any air and then retightened. NOTE: All vehicles are equipped with a pressure hold-off valve. The valve is located (in the combination valve) on the left frame rail. The hold off valve balances front and rear braking force to improve braking and steering control on icy surfaces. The valve shuts off the flow of brake fluid between 3 and 135 PSI. Because the valve shuts off flow in this pressure range the valve must be held open manually -- using tool C-4121 or equivalent -- when pressure bleeding the system. Gravity and pedal bleeding DO NOT require holding this valve open. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 3518 Brake Master Cylinder: Service and Repair Master Cylinder Replacement Aluminum Master Cylinder Master Cylinder 1. Disconnect primary and secondary brake tubes from master cylinder. 2. Install plugs in the outlets of master cylinder. 3. Remove nuts that attach master cylinder to power brake unit. 4. Slide master straight out from power brake unit. Cast Iron Master Cylinder Fig 1 Cast Iron Master Cylinder Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 3519 Fig 2 Cast Iron Master Cylinder (Top View) 1. Disconnect primary and secondary brake tubes from master cylinder. 2. Remove nuts that attach master cylinder to power brake unit. 4. Slide master straight out from power brake unit. Aluminum Master Cylinder Master Cylinder 1. Position master cylinder over studs of power brake booster. 2. Align push rod with master cylinder piston. 3. Install attaching nuts and tighten to specification 20-23 Nm (170-230 in lb). 4. Connect brake tubes and tighten to specification 19 Nm (170 in lb). 5. Bleed brake system being sure to maintain the master cylinder fluid level. For additional information see Notes, Warnings, and Hints. See: Fundamentals and Basics Cast Iron Master Cylinder Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 3520 Fig 1 Cast Iron Master Cylinder Fig 3 Cast Iron Master Cylinder (Exploded View) 1. Position master cylinder on vehicle. 2. Install attaching nuts and tighten to specification 23 Nm (200 in lb). 3. Connect push rod to brake pedal linkage. 4. Connect brake tubes and tighten to specification 19 Nm (170 in lb). 5. Bleed brake system being sure to maintain the master cylinder fluid level. For additional information see Notes, Warnings, and Hints. See: Fundamentals and Basics Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 3521 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Replacement Fig 1 Aluminum Master Cylinder (Cut Away View) Removing Reservoir REMOVAL 1. Clean housing and reservoir. 2. Remove caps and empty brake fluid. 3. Position master cylinder in vise. 4. Rock reservoir from side to side and remove from master cylinder housing. CAUTION: Do not pry off with tool as this may damage reservoir. 5. Remove and discard housing to reservoir grommets. Removing Grommets INSTALLATION 1. Install new housing to reservoir grommets in master cylinder housing. 2. Lubricate reservoir mounting area with brake fluid. CAUTION: Be sure reservoir is positioned properly! All lettering should be readable from the drivers side of the master cylinder. 3. Place reservoir in position over grommets and seat reservoir with a rocking motion onto master cylinder housing. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 3522 4. Be sure reservoir is seated. The bottom of the reservoir should touch the top of the grommet. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Page 3523 Brake Master Cylinder: Tools and Equipment BASIC SERVICE (Removal and Installation) - Fender cover (servicing and bleeding a master-cylinder can be a messy process) WARNING: DOT 3 or 4 brake fluid is very corrosive to the vehicles finish and electrical connections. - Drip pan. - Complete set of combination wrenches or sockets. - Bleeding device: - Pressure bleeder or - Vacuum bleeder or - One-man brake bleeder kit or - Length of clear plastic hose (3/16 inch ID) and a glass jar. Brake Bleeding Setup - Brake adjusting tool (rear brake adjustment should be checked) - Clean shop towels. OPTIONAL - Master Cylinder bleeding kit (contains plastic fittings and hoses used for bleeding master cylinders) - Suction bulb (for removing brake fluid from reservoir) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints Brake Master Cylinder: Fundamentals and Basics Notes, Warnings, and Hints REMOVAL WARNING: DOT 3 or DOT 4 brake fluid is very corrosive to your vehicles finish. Removing master cylinders can be a messy process. To prevent or minimize any possible damage perform the following: Siphon all brake fluid from the master-cylinder reservoir prior to removal. - Use a fender cover to protect the vehicles finish. - Use a drip pan to catch all fluid that leaks from the master-cylinder during removal. - Any brake fluid which contacts the vehicles finish should be washed off immediately. - Any brake fluid which drips onto electrical connections should be immediately removed (aerosol brake cleaner works well for this). After the brake lines have been disconnected from the master-cylinder place vacuum caps over ends of the lines to prevent further leakage or contamination. Once the master-cylinder has been removed place it in a drip pan. Although the reservoir is empty, brake fluid trapped within the cylinder bore will continue to slowly leak out. INSTALLATION Prior to installation the master-cylinder should be bench bled (this can be done on the vehicle but it is much easier on a workbench. NOTE: Normal brake bleeding procedures will not remove air which is trapped in the cylinder bore area of a master-cylinder. Attach the brake line fittings prior to snugging down the master-cylinder retaining bolts. The fittings are much easier to start turning when the master-cylinder is still loose. WARNING: Remember to tighten the retaining bolts after the brake lines are installed and tightened. When snugging down the retaining bolts, alternately tighten them in small increments. This prevents the master-cylinder or push rod from becoming cocked. Upon installing the master-cylinder the entire brake system (front and rear) will need to be bled. Air enters the brake system as soon as the brake lines are removed. It only requires a very small amount of air in the system to create a soft brake pedal. WARNING: Never test drive a vehicle after a master-cylinder replacement until a firm brake pedal with a 75% reserve is established. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 3526 Brake Master Cylinder: Fundamentals and Basics Parts Reminder List RECOMMENDED PARTS Basic Service, Replacement New or rebuilt master-cylinder - Fresh/New brake fluid Optional Aerosol brake cleaner. New or Rebuilt Master Cylinder Always closely compare the new master-cylinder with the old master-cylinder. Minor variations in the size and depth of the primary piston can result in significant reductions in braking performance. - Examine the end of the master-cylinder where the pushrod contacts the piston. The depth and diameters of the pistons should match. Brake Fluid Proper bench bleeding the master-cylinder and flushing the brake system will require a minimum of 16 oz of brake fluid. - Never Mix DOT 3 (light amber in color) with DOT 5 (purple in color). There have been reports of damage to brake system seals when DOT 3 and DOT 5 fluids are mixed - Always store brake fluid in a sealed container. When left open brake fluid will absorb moisture from the air. This reduces the boiling point of the brake fluid and could lead to a soft pedal or brake system failure during prolonged or emergency braking. - Never add automatic transmission fluid, engine oil, or power steering fluid to the master-cylinder. Petroleum based fluids will cause the rubber seals and gaskets in the brake system to swell and leak. Aerosol Brake Cleaner Commercially produced aerosol brake cleaners are designed to effectively clean brake systems while not leaving an oily residue. - Do not use carburetor cleaner or solvent based products to clean brake system components. These products will leave a residue which could contaminate the brake fluid or cause a reduction in braking performance. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 3527 Brake Master Cylinder: Fundamentals and Basics Master Cylinder / Brake Pedal Relationship MASTER CYLINDER / BRAKE PEDAL RELATIONSHIP WARNING: Master Cylinders can be easily misdiagnosed for problems related to excessive brake pedal travel. Excessive brake pedal travel is often associated with a defective master-cylinder, however total pedal travel is affected by a wide variety of components and issues. Issues Affecting Pedal Travel Brake Fluid Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 3528 - Brake fluid which is contaminated with air or water will significantly add to the amount of pedal travel. - Pure DOT 3 (or 4) brake fluid is incompressible (allowing for a solid, firm pedal). A small amount of air trapped in the brake fluid will require extra effort from the master-cylinder to compress it, resulting in a soft and spongy pedal. - During prolonged or severe braking the brake fluid temperature can rapidly rise above 212 degrees F. When this occurs any water in the brake fluid will boil into steam (which is compressable) and create a soft and spongy pedal. Rear Brake Shoe Adjustment Drum brake system utilize return springs to pull the shoes away from the drums when not in use. The amount of distance the shoes have to extend to meet the drums greatly affects the amount of pedal travel. - Shoes/Linings which are badly out of adjustment can by themselves result in a brake pedal sinking all the way to the floor NOTE: Improperly adjusted rear shoes/linings also affect the parking brake. Calipers Excessive rotor wobble caused by a warped rotor or loose/worn wheel bearings can knock the caliper piston further inward from its normal resting position. This results in additional pedal travel required to extend the piston and apply the brakes. Drum Expansion Drums which are worn past their "Discard" thickness are prone to expanding outwards into an oval shape during heavy braking. This drum expansion results in additional brake pedal travel. Brake Fade During prolonged or severe braking, the amount of pedal effort/travel required to slow the vehicle increases as the ability of the brakes to dissipate heat decreases. - As the brake linings heat up, their "coefficient of friction" is reduced (they become slicker). As the coefficient of friction is reduced, more hydraulic pressure is required to stop the vehicle. More hydraulic pressure results in more heat which then results in more pedal fade. - As the brake linings, rotors, and drums begin to wear, their ability to absorb and release heat is reduced significantly. This makes worn brakes more prone to "pedal fade". NOTE: Prior to replacing a master-cylinder, verify the entire brake system is functioning properly. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Fundamentals and Basics > Notes, Warnings, and Hints > Page 3529 Brake Master Cylinder: Fundamentals and Basics Bench Bleeding Notes BENCH BLEEDING Why A master-cylinder will develop little or no pressure if air is trapped in cylinder bore. Normal brake bleeding will not remove air trapped within the master-cylinder. How Clamp the master-cylinder securely in a vice. It is usually best to clamp the side of the vice onto the flat surface that is used to secure the master-cylinder to the brake booster. There are two basic methods for bleeding master-cylinder, one utilizes stroking the master-cylinder to expel air from the cylinder bore while the other utilizes a large syringe to backflush fluid from the outlet ports to the reservoir. Stroking Fill the master-cylinder with clean brake fluid. - The brake line fittings on the master-cylinder should be capped or plugged. NOTE: Special "bench bleeding" plastic fittings are available which allow for recirculating the brake fluid back into the reservoir. - Using a dull object, slowly stroke the master-cylinder piston, air and brake fluid will be expelled from the brake line fittings. Prior to releasing the piston plug or cap the outlet ports. - Repeat this procedure 8-10 times or until no air is emitted from the outlet ports. - When finished, cap the outlet ports and install the master-cylinder. Syringe Fill the syringe (one especially designed for brake bleeding) with clean brake fluid. - Insert the end of the syringe into one of the outlet ports on the master-cylinder. - Slowly compress the syringe and back flush the brake fluid through the master-cylinder. - A combination of air and brake fluid will be emitted from the inlet port in the fluid reservoir. - Repeat this procedure until only brake fluid is emitted into the reservoir. - Cap the outlet ports and install the master-cylinder. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder Bleeder Bolt 95 in.lb Rear Wheel Cylinder Mounting Bolt 15 in.lb Wheel Cylinder Flex Hose 25 ft.lb Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Page 3533 Fig 2 Rear Wheel Cylinder 11 And 12 Inch Brakes Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Page 3534 Wheel Cylinder: Description and Operation Fig 2 Rear Wheel Cylinder 11 And 12 Inch Brakes Fig 1 Wheel Cylinder Installation The piston boots are of the press-on type and prevent moisture from entering the wheel cylinder. To perform service operations or inspections of the wheel cylinder , it will be necessary to remove the cylinders from the support plate and disassemble on the bench. CAUTION: Wheel cylinder with cup expanders MUST have cup expanders after any service procedures (reconditioning or replacement). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal Wheel Cylinder: Service and Repair Wheel Cylinder Removal For additional information see Notes, Warnings and Hints. Fig 1 Brake Tube Disconnected 1. Remove brake shoes. - Replace shoes if soaked with grease or brake fluid). 2. Disconnect brake tube from wheel cylinder. Fig 2 Removing Or Installing Wheel Cylinder 3. Remove wheel cylinder attaching bolts, then pull wheel cylinder assembly out of support plate. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 3537 Wheel Cylinder: Service and Repair Wheel Cylinder Installation For additional information see Notes, Warnings and Hints. Brake Shoe Contact Pads On Backing (Support) Plate 1. Apply RTV sealant around wheel cylinder mounting surface. Fig 1 Wheel Cylinder Installation Fig 2 Removing Or Installing Wheel Cylinder Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 3538 Fig 1 Brake Tube Disconnected 2. Slide wheel cylinder into position on support plate. 3. Install mounting screws and tighten as specified. 4. Connect brake tube to wheel cylinder. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 3539 Wheel Cylinder: Service and Repair Cleaning and Inspection Fig 2 Rear Wheel Cylinder 11 And 12 Inch Brakes 1. With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. 2. Block brake pedal in stroke position. 3. Visually check the boots for cuts, tears, or heat cracks. - If any of these conditions exist, the wheel cylinders should be completely cleaned, inspected and new parts installed. NOTE: A slight amount of fluid on the boot may not be a leak, but may be preservative fluid used at assembly. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Wheel Cylinder Removal > Page 3540 Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul For additional information see Notes, Warnings and Hints. Fig 2 Rear Wheel Cylinder 11 And 12 Inch Brakes NOTE: To perform service operations or inspections of the wheel cylinders, it will be necessary to remove the cylinders from the support plate and disassemble on the bench. CAUTION: Wheel cylinders with cup expanders MUST have cup expanders after any service procedures (reconditioning or replacement). DISASSEMBLING WHEEL CYLINDERS 1. Using a suitable tool, pry boots away from cylinders and remove. 2. Remove push rods. 3. Press In on one piston to force out other piston, cup, spring -- with cup expanders -- cup and piston. 4. Wash wheel cylinder, pistons, and spring in clean brake fluid or alcohol. - Clean thoroughly and blow dry with compressed air. CAUTION: Do not use a rag as lint from the rag will adhere to bore surfaces. INSPECTION Inspect cylinder bore and piston for scoring and pitting. Wheel cylinder bores and pistons that are badly scored or pitted should be replaced. - Cylinder walls that have light scratches, or show signs of corrosion, can usually be cleaned with crocus cloth, using a circular motion. - Black stains on the cylinder walls are caused by piston cups and will not impair operation of cylinder. ASSEMBLING WHEEL CYLINDERS NOTES: - Before assembling the pistons and new cups in the wheel cylinders, dip them in clean brake fluid. - If the boots are deteriorated, cracked or do not fit tightly on the push rods or the cylinder casting, install new boots. 1. Coat cylinder bore with clean brake fluid. 2. Install expansion spring with cup expanders in cylinder. 3. Install cups in each end of cylinder with open end of cups facing each other. 4. Install piston in each end of cylinder having the flat face of each piston contacting the flat face of each cup, already installed. 5. Install a boot over each end of cylinder and press over ends until boot is seated against cylinder shoulder. Use care not to damage boot. 5. Lubricate spherical end of each push rod with brake fluid and insert each into boot. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Testing and Inspection Parking Brake Cable: Testing and Inspection Inspect parking brake cable ends, inspect cables for kinks, fraying and elongation, and replace as necessary. TIP: Use a small hose clamp to compress clamp where it enters backing plate to remove. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Testing and Inspection > Page 3545 Parking Brake Cable: Adjustments 1. Release parking brake lever and loosen cable adjusting nut to be sure cable is slack. 2. With rear wheel brakes properly adjusted tighten cable adjusting nut until a slight drag is felt when the rear wheels are rotated. Then loosen the cable adjusting nut until both rear wheels can be rotated freely. 3. To complete the operation, back off an additional two turns of the cable adjusting nut. 4. Apply and release parking brake several times to be sure rear wheels are not dragging when cable is in released position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Parking Brake Warning Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3550 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3551 Parking Brake Warning Switch: Electrical Diagrams Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3552 Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Hydraulic Brake Booster > Component Information > Description and Operation > Hydro-Boost Hydraulic Brake Booster: Description and Operation Hydro-Boost Fig. 1 Sectional view of typical Bendix Hydro-Boost unit Fig. 2 Typical Hydro-Boost unit disassembled The Hydro-Boost system provides an additional cylinder in the brake system. This cylinder contains no brake fluid. The Hydro-Boost cylinder is hydraulically operated, by pressurized fluid from the power steering pump, providing power assist to operate a dual master cylinder brake system. The booster is composed of two sections; the linkage section and the power section. The booster is designed so that if a total absence of power assist occurs, the brakes can be applied manually, but somewhat greater pressure on the brake Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Hydraulic Brake Booster > Component Information > Description and Operation > Hydro-Boost > Page 3558 pedal is required. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Hydraulic Brake Booster > Component Information > Description and Operation > Hydro-Boost > Page 3559 Hydraulic Brake Booster: Description and Operation Hydro-Boost II Hydro-Boost II is an hydraulically operated power brake booster. The hydraulic brake booster consists of an open center spool valve and an hydraulic cylinder combined into a single housing. The power steering pump provides the hydraulic fluid pressure to operate both the power brake booster and the power steering gear. A dual master cylinder is bolted to the brake booster and is operated by a pushrod projecting from the booster cylinder bore. The Hydro-Boost II also has an accumulator system which stores sufficient fluid under pressure to provide one power assisted brake application when steering pump failure occurs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Hydraulic Brake Booster > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Hydraulic Brake Booster: Initial Inspection and Diagnostic Overview Keep all disassembled parts clean until assembly. Lubricate all seals and metal friction points with power steering fluid. When unit is disassembled, all seals and tube inserts should be replaced. These parts are available in replacement kits. If any accumulator valve components are damaged or lost, replace all valve components. 1. Inspect spool valve and spool valve bore for corrosion, nicks, scoring or other damage. Discoloration of the spool or bore, particularly in the groove areas, is not harmful and replacement is not necessary. 2. If spool valve or bore has nicks or scoring that can be felt with a fingernail, the entire booster should be replaced as an assembly. The clearance between the spool valve and the spool valve bore is important. Because of this clearance, the spool valve and the housing make up a selective assembly. The spool valve is selected to match the spool valve bore. 3. Inspect piston for scratches and nicks. If scratches on the outside surface can be felt with a fingernail, replace piston. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Hydraulic Brake Booster > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3562 Hydraulic Brake Booster: Component Tests and General Diagnostics Hydro-Boost Fig. 4 Spool valve inspection 1. Clean all parts in a suitable solvent being careful to avoid losing small parts. 2. Inspect valve spool and valve spool bore in booster housing for corrosion, nicks, scoring or other damage. Discoloration of the spool or bore, particularly in the grooves, is not harmful. 3. If the valve spool or the spool bore has nicks or scoring that can be felt with a fingernail, particularly on the hands, the spool and housing should be replaced as an assembly. The clearance between the valve spool and the spool bore of the housing is important. Because of this, the spool and housing make are made as a selective assembly and therefore can only be replaced as an assembly. 4. Inspect the input rod and piston assembly for corrosion, nicks, scoring or excessive wear. If the piston is damaged, the input rod and piston assembly should be replaced. 5. Inspect piston bore in booster housing for corrosion, nicks, scoring or other damage. If the bore is damaged, the valve spool and housing should be replaced as an assembly. Hydro-Boost II 1. Fill power steering pump until fluid level is at base of pump reservoir neck. 2. Disconnect 12 volt wire from injection pump or distributor, then crank engine for several seconds. Do not start engine. 3. Check fluid level, adding as necessary. 4. Connect 12 volt wire and start engine. 5. Turn steering wheel from stop to stop, then turn off engine. 6. Depress brake pedal four or five times to deplete accumulator vacuum. 7. Check fluid level, adding as necessary. 8. Start engine, turn steering wheel from stop to stop. Turn engine off, and check fluid level. 9. If fluid is extremely foamy, stop engine and let vehicle stand for one hour, then check fluid level, adding as necessary. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Hydraulic Brake Booster > Component Information > Service and Repair > Bleeding Booster Hydraulic Brake Booster: Service and Repair Bleeding Booster 1. Fill oil reservoir to proper level and let stand at least two minutes. 2. Start engine and run momentarily. 3. Add oil as necessary. 4. Repeat above procedure until oil level remains constant after running engine. 5. Raise and support front of vehicle. 6. Turn wheels left and right, lightly contacting stops. 7. Add oil as necessary. 8. Lower vehicle. 9. Start engine and depress brake pedal several times while rotating steering wheel from stop to stop. 10. Turn engine off, then pump brake pedal four or five times to deplete accumulator pressure. 11. Check oil level, filling as necessary. 12. If oil is extremely foamy, allow vehicle to stand several minutes with engine off, then repeat entire procedure. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Hydraulic Brake Booster > Component Information > Service and Repair > Bleeding Booster > Page 3565 Hydraulic Brake Booster: Service and Repair Hydro-Boost Replacement HYDRO-BOOST 1. Pump brake pedal several times to ensure that all pressure is discharged from the accumulator prior to disconnecting hoses from booster. 2. Remove master cylinder attaching nuts and position master cylinder aside. 3. Disconnect and plug all fluid lines from booster ports, then disconnect brake pedal spring. 4. Remove pushrod to pedal attaching bolt. 5. Remove booster attaching nuts, then the booster. 6. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Hydraulic Brake Booster > Component Information > Service and Repair > Bleeding Booster > Page 3566 Hydraulic Brake Booster: Service and Repair Power Booster Overhaul Disassembly Fig. 3 Removing booster pedal rod. 1980-84 Fig. 4 Spool valve inspection 1. Secure booster assembly in vise. 2. On 1980-84 models, proceed as follows: a. Using a chisel and hammer, cut the bracket nut that secures the mounting bracket to the power section. Be careful to avoid damage to the threads on the booster hub. b. Remove pedal rod boot, if equipped. c. Place tool No. J-24569 around pedal rod as shown, then using a suitable punch, shear pedal rod retainer and remove pedal rod. d. Remove rubber grommet from groove near end of pedal rod and from groove inside input rod end. 3. On 1985-87 models, proceed as follows: a. Remove pedal rod boot, if equipped. b. Remove mounting bracket retaining ring and nut, then saw off pedal rod eyelet and separate the input rod, lever and piston assembly from booster cover. 4. On all models, pry plastic guide out of the output pushrod retainer, then disengage tabs of spring retainer from ledge inside opening near master cylinder mounting flange of booster. 5. Remove retainer, piston return spring and output rod. 6. Position drain pan under booster housing, then remove five housing to cover attaching screws. 7. Remove cover from housing, using caution not to damage cover bore, then the housing seal from housing cover. 8. Remove input rod, lever and piston assembly, then the spool valve assembly and spool return spring from the booster housing. Inspect spool valve. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Hydraulic Brake Booster > Component Information > Service and Repair > Bleeding Booster > Page 3567 If spool valve is found to be defective, the valve assembly must be replaced. 9. Remove power piston seal. Fig. 5 Removing accumulator Fig. 6 Removing accumulator valves Fig. 7 Accumulator valves 10. Install accumulator retaining cap tool No. J-26889 over master cylinder stud and install nut as shown. 11. Depress accumulator, using a suitable C-clamp, then insert a punch into hole in housing and remove retaining ring with a suitable screwdriver. 12. Slowly back off C-clamp until tension on the accumulator is released, then remove accumulator and O-ring. 13. If accumulator valve is to be removed, fabricate tool from 0.040 inch diameter wire as shown. Remove dump valve by catching tool under pin guide near center of valve, then remove check valve assembly and seat. 14. Remove hose fitting O-ring, if necessary. 15. Remove spool plug retaining ring, then the spool plug and O-ring. Assembly Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Hydraulic Brake Booster > Component Information > Service and Repair > Bleeding Booster > Page 3568 Fig. 7 Accumulator valves Fig. 8 Installing input rod seals. 1980-84 Fig. 9 Installing input rod & piston assembly into booster 1. Install O-ring onto spool plug, then push spool plug into housing and install retaining ring. 2. Coat piston bore and piston seal with clean power steering fluid, then install seal into bore. Lip of seal must face away from the master cylinder mounting flange. Also, ensure seal is fully seated in the housing. 3. On 1980-84 models, proceed as follows: a. Lubricate input rod end, input rod seals and seal installer with clean power steering fluid. b. Slide seals on tool with the lip of the cups toward open end of tool. c. Slide tool over input rod end and down to the second groove, then slide the forward seal off tool into the groove. d. Install remaining seal in first groove. Ensure seals are fully seated. On JD3 and JD5 models, only one seal is used. 4. On all models, lubricate piston and piston installing tool, then hold large end of tool against the piston. 5. Slide the piston installing tool and piston into piston bore and through piston seal, then remove piston installing tool. 6. Install hose fitting O-ring, if removed. 7. If accumulator valve was removed, install new valve seat into valve bore. The seat can be forced to the bottom by installing the check valve assembly. 8. Install new dump valve over check valve assembly. Ensure dump valve plunger is held in position until installation is complete. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Hydraulic Brake Booster > Component Information > Service and Repair > Bleeding Booster > Page 3569 Fig. 5 Removing accumulator 9. Install spool return spring and spool valve assembly into bore in housing. Extend power piston lever to accept sleeve on spool valve, then slide lever pins into slot in sleeve. 10. Install new housing seal in groove in hosing cover, then lubricate input rod seals. 11. Install housing cover and cover attaching screws. Torque screws to 18-26 ft lb. 12. Install output rod, spring, baffle and new spring retainer, then secure baffle and spring retainer using a suitable tool. 13. Install accumulator seal and accumulator in housing, then place retaining ring over accumulator. 14. Install tool No. J-26889 over accumulator, then using a suitable C-clamp, depress accumulator, and install retaining ring. 15. Remove C-clamp and tool No. J-26889, then check retaining ring for proper installation. 16. Install mounting bracket and bracket attaching nut. Torque attaching nut to 110 ft lb and lock in position. 17. If repair kit contains a grommet retained pedal rod, proceed as follows: a. Install boot on pedal rod, if equipped. b. Install new grommet in groove near end of pedal rod. c. Moisten grommet with water, then insert grommet end of pedal rod into the input rod end of the booster housing. d. Push on end of pedal rod to seat grommet. When grommet is fully seated, pedal rod will rotate freely with no binding. e. Slide open end of boot onto the hub of the booster. 18. If repair kit contains a staked two piece pedal rod, proceed as follows: a. Install boot over externally threaded pedal rod, if equipped, then slide open end of boot onto hub of booster. b. Install locknut onto externally threaded pedal rod. c. Install eyelet pedal rod onto externally threaded pedal rod, then adjust pedal rod and secure with locknut. Hydro-Boost II Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Hydraulic Brake Booster > Component Information > Service and Repair > Bleeding Booster > Page 3570 Fig. 10 Bracket, removal & installation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Hydraulic Brake Booster > Component Information > Service and Repair > Bleeding Booster > Page 3571 Fig. 11 Spool valve, power piston/accumulator and seal, assembly & disassembly Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Power Brake assembly to dash ........................................................................................................... ........................................................ 220 in lb (25 Nm) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Vacuum Brake Booster > Component Information > Specifications > Page 3575 Vacuum Brake Booster: Description and Operation These units are self contained vacuum hydraulic power braking units. They are the vacuum suspended type which use engine intake manifold vacuum and atmospheric pressure for their power, eliminating the need for a vacuum reservoir. A mechanically operated control valve, integral with the vacuum power diaphragms, controls degree of brake application or release depending on amount of foot pressure applied to valve operating rod through the brake pedal linkage. The control valve is a single poppet type valve with the atmospheric port and a vacuum port. The vacuum port seal is a part of the valve body attached to the diaphragm assembly. The atmospheric port is a part of the valve plunger which moves within the valve housing and vacuum power diaphragm assembly. These units require no maintenance and must be replaced as a complete assembly. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Vacuum Brake Booster > Component Information > Specifications > Page 3576 Vacuum Brake Booster: Service and Repair Fig 1 Power Brake Mounting And Related Parts REMOVAL 1. Disconnect vacuum hose from check valve. 2. Remove master cylinder to booster mounting nuts. 3. From under instrument panel, position a small screwdriver between the center tang on the retainer clip and the pin in the brake pedal. Rotate screwdriver enough to allow retainer clip center tang to pass over end of brake pedal pin and pull clip from pin. Discard retainer clip. 4. Remove mounting nuts and slide booster away from dash panel. INSTALLATION 1. Position booster onto dash panel. 2. Install and tighten four mounting nuts to 220 in lb (25 Nm). 3. Install master cylinder to booster and tighten nuts to 200 in lb (23 Nm). 4. connect vacuum hose. 5. Connect push rod to pedal pin and install new retainer clip. 6. Check stop lamp operation and readjust if necessary. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions Brake Fluid Pressure Sensor/Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3582 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3583 Brake Fluid Pressure Sensor/Switch: Electrical Diagrams Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3584 Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3585 Fig. 20 Ignition Switch With Tilt Wheel Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams > Page 3586 Brake Fluid Pressure Sensor/Switch: Testing and Inspection Brake Warning Switch Testing 1. Raise the car on a hoist and open a wheel cylinder bleeder while a helper depresses the brake pedal and observes the warning light. 2. If the light fails to light, inspect for a burned out bulb, disconnected socket, or a broken or disconnected wire at the switch. 3. If the bulb is not burned out and the wire continuity is uninterrupted, check the service brake warning switch operation with a test lamp between the switch terminal and a voltage source. 4. If light still fails to light, disconnect the brake tubes from the valve assembly and install a new valve assembly. 5. If a new valve is installed, bleed the system. CAUTIONS: - Do not disassemble valve to reset the piston. - The warning switch is not serviced separately. Do not remove the switch or attempt to repair. NOTE: After repairing and bleeding the brake system, applying the brakes with moderate force will hydraulically recenter the piston and automatically turn off the warning light. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Parking Brake Warning Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3591 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3592 Parking Brake Warning Switch: Electrical Diagrams Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3593 Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations Clutch Switch: Locations On Clutch Pedal Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3603 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3604 Ignition Switch: Electrical Diagrams Fig. 19 Ignition Switch Less Tilt Wheel & Starter Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3605 Fig. 19 Ignition Switch Less Tilt Wheel & Starter Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3606 Fig. 20 Ignition Switch With Tilt Wheel Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Page 3607 Ignition Switch: Service and Repair Fig. 1 Lock cylinder removal. Less tilt steering wheel MODELS LESS TILT STEERING 1. Disconnect battery ground cable and remove turn signal switch as outlined in this chapter. 2. Remove ignition key lamp assembly attaching screws, then the assembly. 3. Remove snap ring from upper end of steering shaft. 4. Remove bearing housing to lock housing attaching screws, then the bearing housing from the shaft. 5. Remove buzzer switch attaching screws, then the buzzer switch, if equipped. 6. Remove lock lever guide plate attaching screws, then the lock plate. 7. Place lock cylinder in the "Lock" position and remove key. Using a suitable tool, depress spring loaded lock retainer and pull lock cylinder from housing bore. 8. Remove ignition switch attaching screws, then the ignition switch. 9. Reverse procedure to install. Fig. 2 Lock cylinder removal. W/tilt steering wheel MODELS WITH TILT STEERING Fig. 2 Lock cylinder removal. W/tilt steering wheel Ignition Lock, Replace Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Diagrams > Page 3608 The ignition switch and lock assembly are separate units and must be replaced individually. 1. Disconnect battery ground cable and remove turn signal switch as outlined in this chapter. 2. Place lock cylinder in the "Lock" position and remove key. Insert suitable tool into slot next to switch mounting screw boss. 3. Depress spring latch at bottom of slot, then remove lock. 4. To install ignition lock, place lock cylinder in the "Lock" position and remove key. Install lock cylinder assembly into housing, then press inward and move switch actuator rod up and down to align parts. When parts align, the lock cylinder will move inward and a spring loaded retainer will snap into place, locking cylinder into housing. Ignition Switch, Replace The ignition switch is located on the top of the steering column under the instrument panel. To replace it, the steering column should be lowered as follows: 1. Disconnect shift indicator link. 2. Remove nuts securing bracket to dash panel and carefully lower column. 3. Disconnect electrical connector from switch. Ensure switch is in "Accessory" position. 4. Remove switch attaching screws, then the switch. 5. To install ignition switch, place switch slider and lock in the "Accessory" position. 6. Fit actuator rod into switch and assemble to column. 7. Complete assembly in reverse of removal procedure. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair Neutral Safety Switch: Service and Repair 1. Unscrew switch from transmission case, allowing fluid to drain into container. 2. Move shift lever to Park and then to Neutral positions and inspect to ensure switch operating lever is centered in switch opening in case. 3. Screw switch into transmission case, then add fluid to the proper level. 4. Check to ensure proper switch operation. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Testing and Inspection Starter Relay: Testing and Inspection 1. Place transmission in Neutral and apply parking brake. 2. Check for battery voltage between starter relay battery terminal and ground. 3. Connect jumper wire on starter relay between battery and ignition terminals. 4. If engine does not crank, connect a second jumper wire to starter relay between ground terminal and good ground and repeat test. 5. If engine cranks in step 4, transmission linkage is misadjusted or neutral safety switch is defective. 6. If engine does not crank in step 4, starter relay is defective. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Battery - New State of Charge Indicator Battery: Technical Service Bulletins Battery - New State of Charge Indicator Models 1985 Domestic Passenger Cars & Trucks Subject Dual Ball Battery State of Charge Indicator Index ELECTRICAL Date December 10, 1984 No. 08-31-84 During the 1985 model year domestic vehicles will be equipped with a dual ball battery state of charge indicator. The new test indicator will function similar to the present indicator, but will have an added red indicator ball that will appear when the battery state of charge drops below 50 percent (Figure 1). Also, when the red ball appears, the battery state of charge is no longer adequate to assure reliable starting. Battery state of charge should be checked on vehicles that have been stored for extended periods of time prior to retail delivery and charged if found to be inadequate. NOTE: BATTERIES THAT ARE ALLOWED TO SIT AT A LOW STATE OF CHARGE FOR AN EXTENDED PERIOD OF TIME WILL SUFFER PERMANENT DAMAGE AS A RESULT OF SULFATION AND INTERNAL CORROSION. POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Battery - New State of Charge Indicator > Page 3620 FIGURE 1 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Battery - New State of Charge Indicator > Page 3621 Technical Service Bulletin # 080386 Date: 860407 Battery & Charging System - General Information Models All Passenger Cars & Trucks Subject Battery & Charging System Information Index ELECTRICAL Date April 7, 1986 No. 08-03-86 P-1271 This bulletin outlines the proper procedures that should be followed for charging system diagnosis, battery testing, charging, and storage. WARNING: ALL BATTERIES GENERATE HYDROGEN GAS, WHICH IS EXTREMELY FLAMMABLE. IF IGNITED BY A SPARK OR FLAME, THE GAS MAY EXPLODE VIOLENTLY, CAUSING SPRAYING OF ACID, FRAGMENTATION OF THE BATTERY, AND POSSIBLE SEVERE PERSONAL INJURIES. WEAR APPROVED EYE PROTECTION. BATTERY FLUID IS A CORROSIVE ACID. FLUSH ANY CONTACTED AREA WITH WATER IMMEDIATELY AND THOROUGHLY. Vehicle Storage Today's vehicles have electronic components that require memory retention during a KEY OFF condition. Though KEY OFF loads are small, over an extended period of time they will affect the performance of the battery. Storage at low states of charge can result in permanent battery damage due to internal corrosion. Storage at low states of charge will also result in battery freezing. Therefore, vehicles that are NOT to be used for extended periods of time need special attention. To prevent battery damage you should check and charge (until the GREEN DOT appears), if necessary, all batteries upon receipt of vehicles. For vehicles in storage, disconnect the large bullet connector supplying power to the vehicle. Check and charge all batteries prior to delivering the vehicle to the customer. NOTE: THE IGNITION SWITCH MUST BE OFF WHEN CONNECTING OR DISCONNECTING BATTERY CABLES OR CHARGERS. FAILURE TO DO SO MAY RESULT IN DAMAGE TO ELECTRONIC COMPONENTS. Repair Area, Built-In Test & Battery Visual Inspection Information VEHICLES IN THE REPAIR AREA If a vehicle is going to be in the repair area for a prolonged period of time, the technician should disconnect the battery except when battery use is required for the repair. This will avoid battery drains from an open hood, deck lid, doors, etc. The battery is the primary component in the vehicle's electrical system. It is very important that the battery be capable of delivering the current when necessary, as well as accepting current under charging conditions. Another important function of the battery is as a giant capacitor (shock absorber) in the electrical system. It absorbs surges and acts as a buffer to the electrical system under short-term high-load conditions. All vehicles are equipped with maintenance-free batteries. They have nonremovable battery caps, and never require the addition of water. The battery is sealed except for small vent holes in the cover. The ability to seal the battery is a result of special chemical composition changes made within the battery and the plates. These changes allow only very small amounts of gasses to be generated under normal conditions. BUILT-IN TEST INDICATOR The battery contains a visual test indicator, or hydrometer, molded into the top of the battery case. The test indicator will visually display the "state of charge" of the battery. When the battery is at an adequate state of charge (100% to 75%), the indicator will be GREEN. When charging is required, the Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Battery - New State of Charge Indicator > Page 3622 indicator will be BLACK or dark (75% to 50%) or RED (50% to 0%). Replacement of the battery will be necessary if the test indicator is YELLOW or bright in color. This would be an indication of low fluid level. The test indicator is a built-in hydrometer on top of the battery case. it provides visual information for battery testing. The test indicator is to be used with accepted diagnostic procedures only. It should not be used to determine if the battery is good or bad. It is important when observing the test indicator that the battery be relatively level, and the indicator itself be clean. A light may be required to view the indicator. Under normal operating conditions, one of four conditions can be observed with a maintenance-free battery 1. GREEN DOT Any green appearance is interpreted as a "GREEN DOT" (100% to 75% state of charge), and the battery is adequately charged for testing. On rare occasions following prolonged cranking, the green dot may still be visible with a low battery voltage (below 12.4 volts) indicated on your voltmeter. Should this condition occur, charge the battery as described in the shop manual under "Battery Charging Procedures." 2. DARK OR BLACK DOT A DARK or BLACK DOT (50% to 75% state of charge) indication is a result of the battery being partially discharged, but not below the 45% level. The battery should be checked and charged until the GREEN DOT visible prior to performing a load test. 3. RED DOT A RED DOT visible in the viewing port will be an indication that the battery is BELOW a 50% state of charge and it will be necessary to charge the battery until the GREEN DOT is visible, PRIOR to performing any testing. DO NOT let the battery remain in a discharged state as internal damage may occur. WARNING: ON RARE OCCASIONS, THE TEST INDICATOR MAY TURN A "LIGHT YELLOW" OR "BRIGHT" COLOR. THIS INDICATES A LOW ELECTROLYTE LEVEL. THE VEHICLE'S CHARGING SYSTEM SHOULD BE THOROUGHLY CHECKED FOR AN OVERCHARGING CONDITION. ALTHOUGH THE BATTERY MAY BE CAPABLE OF FUTURE SERVICE, REPLACE IT. DO NOT ATTEMPT TO CHARGE, TEST, OR JUMP START THE VEHICLE. BATTERY VISUAL INSPECTION 1. Make sure the ignition switch is in the "OFF" position and all battery feed accessories are off. 2. Disconnect the battery cables at the negative cable first. 3. Remove battery hold-down clamp and remove battery from vehicle. WARNING: CARE SHOULD BE TAKEN, IN THE EVENT THE BATTERY CASE IS CRACKED OR LEAKING, TO PROTECT HANDS FROM THE ELECTROLYTE. A SUITABLE PAIR OF NON-ABSORBENT GLOVES SHOULD BE WORN WHEN REMOVING THE BATTERY BY HAND. 4. Clean the top of the battery with a solution of clean warm water and baking soda. Scrub area with a stiff bristle brush and wipe off with a cloth moistened with ammnonia or baking soda and water. 5. Inspect battery case and cover for cracks. If cracks are present, the battery must be replaced. 6. Inspect the battery tray for damage caused by loss of acid from the battery. If acid damage is present, it will be necessary to clean the area with the same solution as described in Step 4. 7. Clean the battery posts with a suitable battery post cleaning tool. 8. Clean the inside surfaces of the terminal clamps with a suitable battery cleaning tool. Replace damaged or frayed cables and broken terminal clamps. 9. Inspect the battery for damage around the hold-down ledge. If damage is present, replace the battery. 10. Install the battery in the vehicle, making sure that the battery is properly positioned in the battery tray. Install the hold-down clamp and bolt. Tighten the battery hold-down clamp bolt (refer to the service manual for proper torque specification). 11. Connect the cable clamps to the battery posts, making sure that the clamps are flush with the tops of the battery posts. Tighten the clamps securely, and coat all connections with mineral grease after tightening. WARNING: WHEN BATTERIES ARE BEING CHARGED, AN EXPLOSIVE GAS MIXTURE FORMS BENEATH THE BATTERY COVER OF EACH CELL. DO NOT SMOKE NEAR BATTERIES ON CHARGE OR WHICH HAVE RECENTLY Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Battery - New State of Charge Indicator > Page 3623 BEEN CHARGED. DON'T BREAK LIVE CIRCUITS AT THE TERMINALS OF THE BATTERY ON CHARGE, A SPARK WILL OCCUR WHERE THE LIVE CIRCUIT IS BROKEN. KEEP ALL OPEN FLAMES AWAY FROM THE BATTERY. When it is necessary to charge a sealed battery, the following safety procedures must be followed: 1. Do not charge the battery if "GREEN" except immediately following prolonged cranking. 2. Do not charge the battery if the test indicator is a "LIGHT YELLOW" or "BRIGHT" color. REPLACE THE BATTERY. 3. If the battery feels HOT (125 degrees F, 52 degrees C) or if excessive gassing occurs through the vent holes, discontinue charging or reduce the charging rate IMMEDIATELY. CAUTION: CHARGE THE BATTERY ONLY UNTIL THE GREEN DOT APPEARS. DO NOT OVERCHARGE. Slight tapping or shaking of the battery may be necessary to make the-GREEN DOT appear. There are many types of battery charging equipment available. Be sure to follow the instructions of the equipment manufacturer for the necessary preparations and precautions. However, the following items should be observed when slow charging the battery with any type of equipment: 1. If the battery is to remain in the vehicle, disconnect the cables at the battery negative cable first to prevent damage to the electrical system during charging. 2. Thoroughly clean the battery. Refer to "Battery Visual Inspection." Charging Procedure and Recommendations CHARGING PROCEDURE 1. Batteries with the GREEN DOT showing DO NOT require charging unless they have just been discharged (such as a long crank, etc.). 2. Make sure that all charger connections are clean and tight. 3. For best results, batteries should be charged when the electrolyte and the plates are at room temperature. A battery that is extremely cold may not accept current for SEVERAL hours after charging has begun. 4. Charge the battery ONLY until the GREEN DOT appears. The battery should be checked every half hour while charging. Tapping or shaking the battery may be necessary to make the GREEN DOT appear. 5. After charging, the battery should be tested as outlined in "Battery Testing." CHARGING RECOMMENDATIONS DO NOT CHARGE FROZEN BATTERIES. If the state of charge is very low, the battery may freeze. If it is suspected that the battery is frozen, move the battery to a heated area for at least two hours before charging. Do not place battery near open flame. Time Required, Battery Charged & Testing Information CHARGING TIME REQUIRED The time required to charge a battery will vary, depending upon the following factors: 1. Size of the Battery - A completely discharged large heavy-duty battery requires more than twice the recharging as a completely discharged small passenger car battery. 2. Battery Temperature - The charging time required to charge any battery is increased as the temperature goes down. When a fast charger is connected to a cold battery, the current accepted by the battery will remain low. As the battery warms up, it will accept a higher rate of charge. 3. Charger Capacity - A charger that can supply only 5 amps charging current will require a much longer period of charging than one that can deliver a charging current of 30 amps or more. Charging rates of up to 50 amps are generally acceptable PROVIDED the battery does not gas excessively or become over heated. 4. State of Charge - A completely discharged battery will require more than twice as much current input to reach a fully charged state, than a battery that was half discharged when charging began. Because the electrolyte is nearly pure water in a fully discharged battery, it cannot accept current as well as electrolyte. This is the reason the battery will not accept current when the charging cycle first begins. As the battery remains on the charger, the current from the charger causes the electrolytic acid content to rise. This increase in acid content will make the electrolyte a better conductor and the battery accepts a higher charging rate. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Battery - New State of Charge Indicator > Page 3624 Battery chargers vary in the amount of voltage and current that they can supply. Therefore, the time required for the battery to begin accepting measurable current will also vary. REMEMBER, when you begin to charge a battery, it may be several minutes before charging current is measurable. The charging current will then increase rapidly to normal values provided a good charger is used. CHARGING A VERY FLAT OR COMPLETELY DISCHARGED BATTERY Unless this procedure is properly followed, a perfectly good battery may be needlessly replaced. 1. Measure the voltage at the battery terminals with an accurate voltmeter. If it is below 10 volts, the battery will accept current at a very low rate (milliamperes). It could be some time before the charging rate increases. Such low current flow may NOT be detectable on some ammeters. 2. Set the charger to a high setting. 3. Some chargers have a polarity protection feature which prevents charging unless the charger leads are connected to the correct battery terminals. A completely discharged battery may not have enough voltage to activate this circuitry, even though the leads are connected properly. This will make it appear that the battery will not accept a charge. Follow the charger manufacturer's instructions telling how to bypass or override this circuitry so that the charger will turn on and charge a low-voltage battery. 4. Battery chargers vary in the amount of voltage and current they provide. The time required for the battery to accept measurable charger current at various voltages is as follows: Voltage Hours 16.0 volts or more Up to 4 hours 14.0 to 15.9 volts Up to 8 hours 13.9 volts or less Up to 16 hours If the charging current is not up to a measurable amount at the end of the above times, the battery should be replaced. If the charging current is measurable before the end of, or at the end of the above times, the battery is good and charging should be completed in the normal manner. 6. It is recommended that any battery recharged by this procedure be LOAD TESTED prior to returning it to service. BATTERY TESTING Load Test 1. Observe the test indicator for presence of the GREEN DOT. If not visible, charge the battery prior to testing. 2. Observing the polarity, connect a voltmeter and a battery load tester with amp-meter across the battery terminals. 3. Apply a 300 amp load for 15 seconds to remove the surface charge from the battery, and then remove the load. 4. Wait at least 15 seconds to let the battery recover, and apply the specified load to the battery. 5. Read the voltage after 15 seconds with the load applied, then remove the load. 6. If the voltage does NOT drop below the minimum voltage listed in the load chart, the battery is good and should be returned to service. NOTE: THE BATTERY TEMPERATURE MUST BE ESTIMATED BY THE TEMPERATURE THAT THE BATTERY HAS BEEN EXPOSED TO FOR THE FEW HOURS PRIOR TO TESTING. 7. If the battery passes the load test, no further tests are required and it should be returned to service. If it fails the load test, check further to determine whether it should be charged or replaced. LOAD TEST CHART Minimum Voltage Temperature F 9.6 70 and above 9.5 60 9.4 50 9.3 40 9.1 30 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Battery - New State of Charge Indicator > Page 3625 8.9 20 8.7 10 8.5 0 Open Circuit Voltage Test & Possible Causes of Battery Failure Information Open Circuit Voltage Test If the battery fails the load test, check the state of charge. The open circuit or no-load voltage test is a good measure of the state of charge after the battery has stabilized from the load test. Be sure to let the battery recover from the load test for at least two minutes before checking the no-load voltage to estimate the percent of charge. BATTERY PERCENT OF CHARGE CHART Open Circuit Voltage Percent of Charge 11.7 or less 0 12.0 25 12.2 50 12.4 75 12.6 or more 100 Because the voltage changes in the open circuit voltage test are small, most battery testers use special voltmeters with expanded scales to show the percent of charge. If the percent of charge is 75% or more, the battery is considered to be at a nominal state of charge. If the battery failed the load test and is at 75% state of charge or more, it should be replaced. On the other hand, if the battery is under 75%, it should be charged and load tested again. If the battery fails the load test a second time, the battery should be replaced. POSSIBLE CAUSES OF BATTERY FAILURES IN VEHICLE Battery failures are often NOT the fault of the battery, but caused by existing conditions in the vehicle. Some of the most common are: 1. Corroded Battery Posts or Connectors - When charging or replacing a battery, the posts and cables should ALWAYS be thoroughly cleaned. The film of corrosion that accumulates on these connections can cause a poor connection even when the cables are tight. It is also important to check the cables themselves. Corrosion can "WICK" down into the cable beneath the insulation and cause excessive amounts of resistance in the cable. 2. Electrical Leakage or "Key Off" Loads - Vehicles normally have a "Key Off" load or drain due to the requirement of the electronics and computers in the vehicle. A "Key Off" drain of 15 to 25 milliamps is entirely normal, and poses no short-term problems for the battery. There are, however, a number of electrical components in the vehicle that can draw in excess of 50 milliamps and cause a discharged battery. To check for this condition, turn off all accessories in the car and close all doors, trunk, and turn off all lights. If there is an underhood lamp, remove the bulb. Now you can check for a battery draw by either one of the following methods: a. Remove the POSITIVE battery cable, and connect an ohmmeter between the DISCONNECTED battery cable and the vehicle's chassis or engine block. An ohmmeter reading of 100 ohms or less is an indication of a draw that is 0.1 amp or more. This would be excessive and would require correction. b. Remove the NEGATIVE battery cable, and connect an ammeter with a 0 TO 10 AMP SCALE between the cable and the NEGATIVE post of the battery. Observe the reading on the ammeter VERY CLOSELY. If the ammeter indicates a current draw, WAIT 2 MINUTES and again check the meter. Due to such items as illuminated entry systems and ignition key illumination TIMERS, you may have a false indication of current draw until they time out. After 2 minutes the ammeter should show 0 current draw. If it does NOT show 0, there is an excessive draw condition that must be corrected PRIOR to continuing the test. If the ammeter DOES return to ZERO, remove the large scale meter and install an ammeter that will read below ONE ampere. A reading of 0.1 amp or more would indicate an excessive draw condition that must be located and corrected. Further Points to Consider Proper operation of the charging system should be confirmed. The drive belts must be properly tightened, wiring connectors properly attached, the voltage regulator functioning properly, correct alternator output, and no electrical loads left on inadvertently. POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Specifications > Electrical Specifications Battery: Electrical Specifications Standard Battery Standard Battery BCI Group Number 34 Cranking Performance 400 A Optional Battery Optional Battery BCI Group Number 34 Cranking Performance 500 A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Battery > Component Information > Specifications > Electrical Specifications > Page 3628 Battery: Mechanical Specifications Optional Battery Optional Battery BCI Group Number 34 Cranking Performance 500 A Standard Battery Standard Battery BCI Group Number 34 Cranking Performance 400 A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Yellow ID Tag Generator: Specifications Yellow ID Tag Yellow ID Tag, 60 Amp Alternator Yellow ID Tag, 60 Amp Alternator Rated Output 60 A Test Output 57 A at 1250 rpm Note: Minimum, 15 volts at alternator. Field Current Draw 2.5-6.5 A Note: When hand rotated Yellow ID Tag, 117 Amp Alternator Yellow ID Tag, 117 Amp Alternator Rated Output 117 A Test Output 72 A at 900 rpm Field Current Draw 4.5-6 A Note: When hand rotated Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Yellow ID Tag > Page 3634 Generator: Specifications Color Code Brown, Amperage Output Color Code Brown, Amperage Output Rated Output 78 A Test Output 57 A at 1250 rpm Field Current Draw 2.5-6 A Note: When hand rotated Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications > Yellow ID Tag > Page 3635 Generator: Specifications Color Code Violet, Amperage Color Code Violet, Amperage Rated Output 41 A Test Output 40 A at 1250 rpm Field Current Draw 2.5-6.5 A Note: When hand rotated Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Description and Operation > Bosch & Nippondenso Alternators Generator: Description and Operation Bosch & Nippondenso Alternators The main components of the alternator are the rotor, stator, rectifier, end shields and drive pulley. Direct current is available at the output "B+" terminal. Alternator output is controlled by voltage regulator circuitry contained within the power and logic modules of the Single Module Engine Controller (SMEC). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Description and Operation > Bosch & Nippondenso Alternators > Page 3638 Generator: Description and Operation Chrysler Alternators The main components of the alternator are the rotor, stator, diodes, end shields and drive pulley. Direct current is available at the output "BAT" terminal. The function of the voltage regulator is to limit output voltage. This is accomplished by controlling the current flow in the rotor field coil, in turn controlling the strength of the rotor magnetic field. The electronic voltage regulator is a sealed, non-adjustable unit. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Description and Operation > Bosch & Nippondenso Alternators > Page 3639 Generator: Description and Operation Mitsubishi Alternators Fig. 1 Wiring diagram of Mitsubishi alternator charging system On these units, the regulator is incorporated into the alternator rear housing. The electronic voltage regulator has the ability to vary regulated system voltage upward or downward as temperature changes. No voltage regulated adjustments are required on these units. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Bosch & Nippondenso Alternators Generator: Testing and Inspection Bosch & Nippondenso Alternators Alternator Output Wire Resistance Test Fig. 1 Alternator output wire resistance test. Bosch & Nippondenso alternators Testing 1. Disconnect battery ground cable. 2. Disconnect "B+" lead at alternator output terminal. 3. Connect a 0-150 amp D.C. ammeter in series between alternator "B+" terminal and disconnected "B+" lead wire. 4. Connect positive lead wire of a suitable voltmeter to disconnected "B+" lead wire, then connect negative lead to battery positive post. 5. Remove air hose between Single Module Engine Controller (SMEC) and air cleaner, then ground one end of a suitable jumper wire and probe green R3 wire on dash side of black 8-way connector. Use caution not to ground J2 wire of 8-way dash connector. Both R3 and J2 wires are green on alternator side of wire connector. On dash side of connector, R3 wire is green, while J2 wire is blue. 6. Connect a suitable engine tachometer, then reconnect battery ground cable. 7. Connect a variable carbon pile rheostat to battery terminals, ensuring carbon piles are in "open" or "off" position. 8. Start engine and operate at idle speed, then adjust carbon pile and engine speed to maintain a 20 amp circuit flow. Note voltmeter reading. Voltmeter reading should not exceed .5 volt. Test Results 1. If a higher than specified voltage drop is indicated, clean and tighten all connectors in charging circuit. A voltage drop test may be performed at each connector to locate point of excessive resistance. 2. If charging circuit resistance test was satisfactory, disconnect battery ground cable, then the ammeter, voltmeter and carbon pile. 3. Remove jumper wire. 4. Connect battery ground cable, then the hose between SMEC and air cleaner. Current Output Test Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Bosch & Nippondenso Alternators > Page 3642 Fig. 2 Alternator current output test. Bosch & Nippondenso alternators Testing 1. Disconnect battery ground cable. 2. Disconnect "B+" lead at alternator output terminal. 3. Connect a 0-150 amp D.C. ammeter in series between alternator "B+" terminal and disconnected "B+" lead wire. 4. Connect positive lead of a suitable voltmeter to "B+" terminal of alternator, then connect negative lead to a suitable ground. 5. Connect a suitable engine tachometer, then reconnect battery ground cable. 6. Connect a variable carbon pile rheostat between battery terminals, ensuring carbon piles are in "open" or "off" position. 7. Remove air hose between Single Module Engine Controller (SMEC) and air cleaner, then ground one end of a suitable jumper wire and probe green R3 wire on dash side of black 8-way connector. Use caution not to ground J2 wire of 8-way dash connector. Both R3 and J2 wires are green on alternator side of wire connector. On dash side of connector, R3 wire is green, while J2 wire is blue. 8. Start engine and operate at idle speed, then adjust carbon pile and engine speed in increments until a speed of 1250 RPM at 15 volts is obtained. Do not allow voltmeter range to exceed 16 volts during testing. Test Results 1. Note ammeter reading. Ammeter reading should be within specified limits noted in specification charts in individual truck chapters. 2. If reading is less than specified, alternator is defective. 3. After completion of current output test, turn off carbon pile and ignition switch, then disconnect battery ground cable. 4. Remove ammeter, voltmeter, tachometer and carbon pile, then reconnect "B+" lead to alternator output terminal. 5. Disconnect jumper wire, then connect air hose from SMEC to air cleaner. 6. Connect battery ground cable. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Bosch & Nippondenso Alternators > Page 3643 Generator: Testing and Inspection Chrysler Alternators Alternator Output Wire Resistance Test Fig. 1 Alternator output wire resistance test (Typical) TESTING 1. Disconnect battery ground cable. 2. Disconnect "Bat" lead at alternator output terminal. 3. Connect a 0-150 amp D.C. ammeter in series between alternator "Bat" terminal and disconnected "Bat" lead wire. 4. Connect positive lead wire of a suitable voltmeter to disconnected "Bat" lead wire, then connect negative lead to battery positive post. 5. Disconnect voltage regulator wiring connector, then using suitable jumper wire, connect wiring connector green regulator field wire to a suitable ground. 6. Connect a suitable engine tachometer, then reconnect battery ground cable. 7. Connect a variable carbon pile rheostat to battery terminals, ensuring carbon piles are in "open" or "off" position. 8. Start engine and operate at idle speed, then adjust carbon pile and engine speed to maintain a 20 amp circuit flow. Note voltmeter reading. Voltmeter reading should not exceed .7 volt on 1980-83 models, or .5 volt on 1984-87 models. TEST RESULTS 1. If a higher than specified voltage drop is indicated, clean and tighten all connectors in charging circuit. A voltage drop test may be performed at each connector to locate point of excessive resistance. 2. If charging circuit resistance test was satisfactory, disconnect battery ground cable, then the ammeter, voltmeter and carbon pile. 3. Remove jumper wire, then connect regulator wire connector. 4. Connect battery ground cable. Current Output Test Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Bosch & Nippondenso Alternators > Page 3644 Fig. 2 Current output test (Typical) TESTING 1. Disconnect battery ground cable. 2. Disconnect "Bat" lead at alternator output terminal. 3. Connect a 0-150 amp D.C. ammeter in series between alternator "Bat" terminal and disconnected "Bat" lead wire. 4. Connect positive lead of a suitable voltmeter to "Bat" terminal of alternator, then connect negative lead to a suitable ground. 5. Disconnect voltage regulator wiring connector, then using suitable jumper wire, connect wiring connector green regulator field wire to a suitable ground. 6. Connect a suitable engine tachometer, then reconnect battery ground cable. 7. Connect a variable carbon pile rheostat between battery terminals, ensuring carbon piles are in "open" or "off" position. 8. Start engine and operate at idle speed, then adjust carbon pile and engine speed in increments until a speed of 1250 RPM at 15 volts is obtained on all units except 1980-84 100, 114 and 117 amp units. On 1980-84 100, 114 and 117 amp units, adjust carbon pile and engine speed to 900 RPM at 13 volts. Do not allow voltmeter range to exceed 16 volts during testing. TEST RESULTS 1. Note ammeter reading. Ammeter reading should be within specified limits noted in specification charts in individual truck chapters. 2. If reading is less than specified, alternator is defective. 3. After completion of current output test, turn off carbon pile and ignition switch, then disconnect battery ground cable. 4. Remove ammeter, voltmeter, tachometer and carbon pile, then reconnect "Bat" lead to alternator output terminal. 5. Disconnect jumper wire from ground, then reconnect voltage regulator wiring connector. 6. Connect battery ground cable. Alternator & Regulator Diagnosis Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Bosch & Nippondenso Alternators > Page 3645 Fig. 5 Charging system diagnosis chart Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Bosch & Nippondenso Alternators > Page 3646 Generator: Testing and Inspection Mitsubishi Alternators Current Output Test Fig. 3 Current output test connections Fig. 4 Alternator test specifications. 1981-85 Fig. 5 Alternator test specifications. 1986-87 1. With ignition switch in the Off position, disconnect battery ground cable, then disconnect battery lead from alternator output terminal. 2. Connect an ammeter set at the 0 to 100 amp scale between alternator output terminal and the disconnected battery lead. 3. Connect positive lead of voltmeter to alternator output terminal and negative lead to ground. 4. Connect suitable tachometer to engine and reconnect battery ground cable. 5. Connect a variable carbon pile regulator between battery terminals. When installing carbon pile regulator, ensure regulator is in Open or Off position. 6. Adjust carbon pile regulator and accelerate engine to the specified RPM, noting ammeter and voltmeter readings. 7. If ammeter reading is less than specified, the alternator is defective. Charging Circuit Resistance Test Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Bosch & Nippondenso Alternators > Page 3647 Fig. 6 Charging circuit resistance test connections 1. Disconnect battery ground cable. 2. Disconnect "BAT" lead at alternator output terminal. 3. Connect an ammeter set at 0 to 100 amp scale in series between alternator output terminal and disconnected lead wire. Connect positive lead to " BAT" terminal and negative lead to disconnected "BAT" lead. 4. Connect positive lead of a suitable voltmeter to disconnected "BAT" lead wire, then connect negative lead to battery positive post. 5. Connect a suitable tachometer to engine, then reconnect battery ground cable. 6. Connect a variable carbon pile regulator between battery terminals. When installing regulator, ensure it is in "open" or "off" position. 7. Start engine, then adjust engine speed and carbon pile regulator to maintain 20 amp circuit flow. Ensure voltmeter reading does not exceed .5 volts. If a higher voltage drop is indicated, proceed as follows: a. Tighten all connections to locate possible source of resistance. b. Inspect and clean each connection. 8. If test proves satisfactory, disconnect battery ground cable, then remove ammeter, voltmeter and carbon pile. 9. Connect battery ground cable. Alternator & Electronic Voltage Regulator Diagnosis Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Bosch & Nippondenso Alternators > Page 3648 Fig. 7 Alternator & electronic voltage regulator diagnosis chart Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Technical Service Bulletins > Customer Interest for Voltage Regulator: > 080985 > Apr > 85 > Radio - Rapid Crackling Noise in FM Mode Voltage Regulator: Customer Interest Radio - Rapid Crackling Noise in FM Mode Models All 1985 Carbureted Vehicles (Except 2.6L Engine) Equipped . With AM/FM Stereo Radio (Sales Code RAL, RAN, or RAY) Subject FM Radio Noise Induced by Electronic Voltage Regulator Index ELECTRICAL Date April 1, 1985 No.. 08-09-85 SYMPTOM/CONDITION Vehicle may exhibit radio interference in the FM mode, best described as a "rapid cracking noise." Intensity may be high or low. It is not a whine or static noise. DIAGNOSIS This condition only applies to subject vehicles built on or before December 21, 1984 MDH 12-12-XX. Check with hood closed and engine running slightly above idle in park or neutral. Tune to weak FM station (prefer using station customer listens to). Switch off all other electrical loads. If noise is heard, have someone disconnect electronic voltage regulator and close the hood. If noise is eliminated, replace electronic voltage regulator with PN 4379100. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 08-20-10-01 FWD . . . . . . . . . 0.2 Hrs. 08-20-10-05 RWD . . . . . . . . . 0.2 Hrs. FAILURE CODE: 58 - Internal Defect Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Voltage Regulator: > 080985 > Apr > 85 > Radio - Rapid Crackling Noise in FM Mode Voltage Regulator: All Technical Service Bulletins Radio - Rapid Crackling Noise in FM Mode Models All 1985 Carbureted Vehicles (Except 2.6L Engine) Equipped . With AM/FM Stereo Radio (Sales Code RAL, RAN, or RAY) Subject FM Radio Noise Induced by Electronic Voltage Regulator Index ELECTRICAL Date April 1, 1985 No.. 08-09-85 SYMPTOM/CONDITION Vehicle may exhibit radio interference in the FM mode, best described as a "rapid cracking noise." Intensity may be high or low. It is not a whine or static noise. DIAGNOSIS This condition only applies to subject vehicles built on or before December 21, 1984 MDH 12-12-XX. Check with hood closed and engine running slightly above idle in park or neutral. Tune to weak FM station (prefer using station customer listens to). Switch off all other electrical loads. If noise is heard, have someone disconnect electronic voltage regulator and close the hood. If noise is eliminated, replace electronic voltage regulator with PN 4379100. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 08-20-10-01 FWD . . . . . . . . . 0.2 Hrs. 08-20-10-05 RWD . . . . . . . . . 0.2 Hrs. FAILURE CODE: 58 - Internal Defect Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Technical Service Bulletins > Page 3662 Voltage Regulator: Specifications System Operating Voltage System Operating Voltage Voltage Setting 14.9-15.9 V at -20 deg F Note: At Test Temperature 13.9-14.6 V at 80 deg F Note: At Test Temperature 13.3-13.9 V at 140 deg F Note: At Test Temperature 13.9 V Note: At Above Test Temperature of 140 deg F (60 deg. C) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Testing and Inspection > Bosch & Nippondenso Alternators Voltage Regulator: Testing and Inspection Bosch & Nippondenso Alternators Voltage regulation is controlled by the SMEC unit. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Testing and Inspection > Bosch & Nippondenso Alternators > Page 3665 Voltage Regulator: Testing and Inspection Chrysler Alternator & Regulator Voltage Regulator Test Fig. 3 Electronic voltage regulator test (Typical) Fig. 4 Regulator test specification chart TESTING Battery must be fully charged for test to be accurate. 1. Clean battery terminals, then connect positive lead of a suitable voltmeter to battery positive post and the negative lead to a suitable ground. 2. Connect an engine tachometer, then start and operate engine at 1250 RPM with all lights and accessories in the "off" position. 3. Note voltmeter readings, then refer to voltage chart. An ammeter reading registering an immediate charge, then gradually returning to normal, is normal. The duration the ammeter remains positioned to the right depends on cranking time. TEST RESULTS 1. If voltage is fluctuating or below limits, proceed as follows: a. Ensure voltage regulator has a proper ground through regulator case, mounting screws and chassis. b. Place ignition switch in "off" position, then disconnect voltage regulator connector and inspect for a possible open circuit. c. Place ignition switch in "on" position. Do not start engine or distort terminals with voltmeter probe. d. Ensure battery voltage exists at blue and green leads at voltage regulator wiring harness terminals, then place ignition switch in "off" position. If steps a through d are satisfactory, replace voltage regulator. 2. If voltage is above limits, proceed as follows: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Testing and Inspection > Bosch & Nippondenso Alternators > Page 3666 a. Place ignition switch in "off" position, then disconnect voltage regulator connector. b. Place ignition switch in "on" position. Do not start engine or distort terminals with voltmeter probe. c. Ensure battery voltage exists at blue and green leads at voltage regulator wiring harness terminals, then place ignition switch in "off" position. If results of steps a, b and c are not satisfactory, replace voltage regulator. 3. Remove voltmeter and tachometer. Alternator & Regulator Diagnosis Fig. 5 Charging system diagnosis chart Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Testing and Inspection > Bosch & Nippondenso Alternators > Page 3667 Voltage Regulator: Testing and Inspection Mitsubishi Alternators Voltage Regulator Test Fig. 2 Voltage regulator test connections 1. With ignition switch in Off position, disconnect alternator battery lead at output terminal and connect ammeter in series between alternator and disconnected lead. 2. Connect a voltmeter between alternator L terminal and ground. Voltmeter should indicate zero voltage. If voltage is present, the alternator or charging system wiring is defective. 3. Place ignition switch in the On position and note voltmeter reading. Voltmeter reading should be 1 volt or less. If a higher reading is indicated, the alternator is defective. 4. Connect a tachometer to engine, then start and operate engine at approximately 2000 to 3000 RPM and note ammeter reading. When starting engine, ensure no starting current is applied to ammeter. 5. If ammeter reading is 5 amps or less on 1981-83 units, or 10 amps or less on 1984-86 models, check voltmeter reading with engine operating at 2000 to 3000 RPM. The charging voltage should be 14.4 volts at 68° F. 6. If ammeter reading is above 5 amps on 1981-83 models or above 10 amps on 1984-87 models, continue to charge battery until reading drops to less than 5 amps on 1981-83 models, or to less than 10 amps on 1984-87 models. If voltage is not within limits, alternator is defective. An alternative method to limiting charging current is to connect a {1/4} ohm (25 watt) resistor in series with battery. Alternator & Electronic Voltage Regulator Diagnosis Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Testing and Inspection > Bosch & Nippondenso Alternators > Page 3668 Fig. 7 Alternator & electronic voltage regulator diagnosis chart Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations Clutch Switch: Locations On Clutch Pedal Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Resistor <--> [Ignition Ballast Resistor] > Component Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Resistor <--> [Ignition Ballast Resistor] > Component Information > Specifications > Page 3676 Ignition Resistor: Locations Ballast Resistor Left side of fire wall, engine compartment. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair Ignition Lock: Service and Repair Fig. 1 Lock cylinder removal. Less tilt steering wheel MODELS LESS TILT STEERING 1. Disconnect battery ground cable and remove turn signal switch as outlined in this chapter. 2. Remove ignition key lamp assembly attaching screws, then the assembly. 3. Remove snap ring from upper end of steering shaft. 4. Remove bearing housing to lock housing attaching screws, then the bearing housing from the shaft. 5. Remove buzzer switch attaching screws, then the buzzer switch, if equipped. 6. Remove lock lever guide plate attaching screws, then the lock plate. 7. Place lock cylinder in the "Lock" position and remove key. Using a suitable tool, depress spring loaded lock retainer and pull lock cylinder from housing bore. 8. Remove ignition switch attaching screws, then the ignition switch. 9. Reverse procedure to install. Fig. 2 Lock cylinder removal. W/tilt steering wheel MODELS WITH TILT STEERING Fig. 2 Lock cylinder removal. W/tilt steering wheel Ignition Lock, Replace Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Page 3680 The ignition switch and lock assembly are separate units and must be replaced individually. 1. Disconnect battery ground cable and remove turn signal switch as outlined in this chapter. 2. Place lock cylinder in the "Lock" position and remove key. Insert suitable tool into slot next to switch mounting screw boss. 3. Depress spring latch at bottom of slot, then remove lock. 4. To install ignition lock, place lock cylinder in the "Lock" position and remove key. Install lock cylinder assembly into housing, then press inward and move switch actuator rod up and down to align parts. When parts align, the lock cylinder will move inward and a spring loaded retainer will snap into place, locking cylinder into housing. Ignition Switch, Replace The ignition switch is located on the top of the steering column under the instrument panel. To replace it, the steering column should be lowered as follows: 1. Disconnect shift indicator link. 2. Remove nuts securing bracket to dash panel and carefully lower column. 3. Disconnect electrical connector from switch. Ensure switch is in "Accessory" position. 4. Remove switch attaching screws, then the switch. 5. To install ignition switch, place switch slider and lock in the "Accessory" position. 6. Fit actuator rod into switch and assemble to column. 7. Complete assembly in reverse of removal procedure. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions Ignition Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3685 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3686 Ignition Switch: Electrical Diagrams Fig. 19 Ignition Switch Less Tilt Wheel & Starter Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3687 Fig. 19 Ignition Switch Less Tilt Wheel & Starter Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3688 Fig. 20 Ignition Switch With Tilt Wheel Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Page 3689 Ignition Switch: Service and Repair Fig. 1 Lock cylinder removal. Less tilt steering wheel MODELS LESS TILT STEERING 1. Disconnect battery ground cable and remove turn signal switch as outlined in this chapter. 2. Remove ignition key lamp assembly attaching screws, then the assembly. 3. Remove snap ring from upper end of steering shaft. 4. Remove bearing housing to lock housing attaching screws, then the bearing housing from the shaft. 5. Remove buzzer switch attaching screws, then the buzzer switch, if equipped. 6. Remove lock lever guide plate attaching screws, then the lock plate. 7. Place lock cylinder in the "Lock" position and remove key. Using a suitable tool, depress spring loaded lock retainer and pull lock cylinder from housing bore. 8. Remove ignition switch attaching screws, then the ignition switch. 9. Reverse procedure to install. Fig. 2 Lock cylinder removal. W/tilt steering wheel MODELS WITH TILT STEERING Fig. 2 Lock cylinder removal. W/tilt steering wheel Ignition Lock, Replace Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Diagrams > Page 3690 The ignition switch and lock assembly are separate units and must be replaced individually. 1. Disconnect battery ground cable and remove turn signal switch as outlined in this chapter. 2. Place lock cylinder in the "Lock" position and remove key. Insert suitable tool into slot next to switch mounting screw boss. 3. Depress spring latch at bottom of slot, then remove lock. 4. To install ignition lock, place lock cylinder in the "Lock" position and remove key. Install lock cylinder assembly into housing, then press inward and move switch actuator rod up and down to align parts. When parts align, the lock cylinder will move inward and a spring loaded retainer will snap into place, locking cylinder into housing. Ignition Switch, Replace The ignition switch is located on the top of the steering column under the instrument panel. To replace it, the steering column should be lowered as follows: 1. Disconnect shift indicator link. 2. Remove nuts securing bracket to dash panel and carefully lower column. 3. Disconnect electrical connector from switch. Ensure switch is in "Accessory" position. 4. Remove switch attaching screws, then the switch. 5. To install ignition switch, place switch slider and lock in the "Accessory" position. 6. Fit actuator rod into switch and assemble to column. 7. Complete assembly in reverse of removal procedure. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Service and Repair Neutral Safety Switch: Service and Repair 1. Unscrew switch from transmission case, allowing fluid to drain into container. 2. Move shift lever to Park and then to Neutral positions and inspect to ensure switch operating lever is centered in switch opening in case. 3. Screw switch into transmission case, then add fluid to the proper level. 4. Check to ensure proper switch operation. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications Starter Motor: Electrical Specifications Starter Number - 4111855 or 4111860 Starter Number - 4111855 or 4111860 Model Number 4111855 or 4111860 Note: Stamped on plate riveted to housing. Brush Spring Tension 32-36 oz No Load Test 90 A at 3700 rpm Note: Maximum amps. Minimum RPM. Note: At 11 volts. Torque Test 475-550 A Note: At 4 volts. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications > Page 3698 Starter Motor: Mechanical Specifications Starter Number - 4111855 or 4111860 Starter Number - 4111855 or 4111860 Model Number 4111855 or 4111860 Note: Stamped on plate riveted to housing. Brush Spring Tension 32-36 oz No Load Test 90 A at 3700 rpm Note: Maximum amps. Minimum RPM. Note: At 11 volts. Torque Test 475-550 A Note: At 4 volts. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Description and Operation > Bosch, Mitsubishi & Nippondenso Starters Starter Motor: Description and Operation Bosch, Mitsubishi & Nippondenso Starters Two types of starters are used. The first type is a direct drive starter motor with an overrunning clutch type starter drive. A solenoid switch is mounted on the starter motor. The second type is a permanent magnet reduction gear starter. A planetary gear train transmits power between starter motor and pinion shaft. The structure is different on both type starters, but electrical wiring is the same. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Description and Operation > Bosch, Mitsubishi & Nippondenso Starters > Page 3701 Starter Motor: Description and Operation Chrysler Reduction Gear Starters Fig. 1 Chrysler built reduction gear starter. Gasoline engines This reduction gear starting motor has an armature-to-engine crankshaft ratio of 45 to 1; a 2 to 1 or 3- {1/2} to 1 reduction gear set is built into the motor assembly. The starter utilizes a solenoid shift. The housing of the solenoid is integral with the starter drive end housing. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Bosch, Mitsubishi & Nippondenso Starters Starter Motor: Testing and Inspection Bosch, Mitsubishi & Nippondenso Starters Diagnosis Fig. 1 Starter motor diagnosis Amperage Draw Test 1. Run engine until it reaches operating temperature, then turn engine off. 2. Connect a suitable battery-starter tester according to manufacturer's instructions. 3. Turn battery-starter tester control knob to "OFF" position. 4. Turn voltmeter selector knob to "16 VOLT" position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Bosch, Mitsubishi & Nippondenso Starters > Page 3704 5. Turn battery-starter function selector to "STARTER SYSTEM TEST" (0-500 amp scale). 6. Connect red positive ammeter lead to positive battery terminal and the black negative ammeter lead to negative battery terminal. 7. Connect red positive voltmeter lead to positive battery terminal and the black negative voltmeter lead to the negative battery terminal. 8. Connect a remote starter jumper according to manufacturer's instructions. Do not crank engine excessively during testing. 9. Disconnect coil wire from distributor cap center tower and secure to good ground. 10. Crank engine with remote starter switch and observe exact voltmeter reading, then stop cranking engine. 11. Turn tester control knob clockwise until voltmeter reads exactly the same as when engine was being cranked. Ammeter should read 120-160 amps on direct drive units or 150-210 amps on gear reduction units. Circuit Resistance Test On 1986-87 reduction gear starters, perform circuit resistance test, refer to "Chrysler Reduction Gear Starter" section. Insulated Circuit Test 1. Turn voltmeter selector knob to 4 volt position. 2. Disconnect ignition coil secondary cable. 3. Connect voltmeter positive lead to battery positive post and voltmeter negative lead to solenoid connector that connects to starter field coils. It may be necessary to peel back rubber boot on solenoid to reach solenoid connection. Voltmeter will read off scale to right until starter is actuated. 4. Connect remote control starter switch to battery solenoid terminal of starter relay. 5. Crank engine with remote control starter switch while observing voltmeter reading. If voltmeter reading exceeds .3 volt, there is high resistance in starter insulated circuit, proceed as follows: a. Remove voltmeter lead from solenoid connector and connect to following points, repeating test at each connection. Starter terminal of solenoid, battery terminal of solenoid, battery cable terminal at solenoid, starter relay and cable clamp at battery. b. A small change will occur each time a normal portion of circuit is removed from test. A definite change in voltmeter reading indicates that last part eliminated in test is at fault. Starter Ground Test 1. Connect voltmeter positive lead to starter through bolt and negative voltmeter lead to battery negative post. 2. Crank engine with remote control starter switch and observe voltmeter reading. 3. If voltmeter reading exceeds .2 volt, make following tests to isolate point of excessive voltage loss, repeating test at each connection; starter drive housing, cable terminal at engine, cable clamp at battery. 4. A small change will occur each time a normal portion of circuit is removed from test. A definite change in voltmeter reading indicates last part eliminated in test is at fault. Starter Resistance Test 1. Disconnect positive battery cable and connect a 0-300 scale ammeter between disconnected lead and battery terminal post. 2. Connect a voltmeter, graduated in tenths, between positive post on battery and starter relay terminal on starter solenoid. 3. Crank engine while observing reading on voltmeter and ammeter. A voltage reading exceeding .3 volt indicates high resistance caused by loose circuit connections, a faulty cable, burned starter relay or solenoid switch contacts. A high current combined with slow cranking speed indicates need for starter repair. 4. Reconnect positive battery lead to battery. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Bosch, Mitsubishi & Nippondenso Starters > Page 3705 Starter Motor: Testing and Inspection Chrysler Reduction Gear Starters Diagnosis Fig. 2 Starter motor diagnosis (Part 1 of 2) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Bosch, Mitsubishi & Nippondenso Starters > Page 3706 Fig. 2 Starter motor diagnosis (Part 2 of 2) In-Vehicle Testing 1983-85 MODELS Amperage Draw Test Perform amperage draw test, refer to "Bosch, Mitsubishi & Nippondenso Starters" section. Amperage should be 165-180 amps for 1983-85 models with 6-225 and V8-318 engines, 180-200 amps for 1983-85 models with V8-360 engines. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Bosch, Mitsubishi & Nippondenso Starters > Page 3707 Fig. 3 Circuit resistance chart. 1980-85 Circuit Resistance Test 1. Connect voltmeter leads across each connection shown in circuit resistance chart. 2. If readings are higher than specified, clean or repair connection, then repeat test. Starter Solenoid Test 1. Connect heavy jumper wire on starter relay between battery and solenoid terminals. 2. If starter does not crank, or solenoid chatters, check wiring and connectors from relay to starter for loose or corroded connections, then repeat test. 3. If engine still will not crank, repair or replace starter as necessary. Starter Relay Test (Automatic Transmissions) 1. Place transmission in Neutral, then connect jumper wire on starter relay between battery and ignition terminals. 2. If engine does not crank, connect a second jumper wire on starter relay between ground terminal and good ground. 3. Repeat test. If engine cranks, transmission linkage is misadjusted or neutral safety switch is defective. If engine does not crank, starter relay is defective. Starter Relay Test (Manual Transmissions) 1. Depress clutch pedal, then connect suitable jumper wire on starter relay between battery and ignition terminals. 2. If engine cranks, starter relay is satisfactory. If engine does not crank, connect a second jumper on starter relay between ground terminal and good ground, then repeat test. 3. If engine does not crank, starter relay is defective and should be replaced. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Page 3708 Starter Motor: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect starter cable at starter, then the solenoid lead wire from solenoid. 3. Remove heat shield attaching bolt, then the heat shield if equipped. 4. Remove starter motor attaching bolts, then the oil cooler tube bracket, if equipped with automatic transmission. 5. Remove starter from vehicle. 6. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Testing and Inspection Starter Relay: Testing and Inspection 1. Place transmission in Neutral and apply parking brake. 2. Check for battery voltage between starter relay battery terminal and ground. 3. Connect jumper wire on starter relay between battery and ignition terminals. 4. If engine does not crank, connect a second jumper wire to starter relay between ground terminal and good ground and repeat test. 5. If engine cranks in step 4, transmission linkage is misadjusted or neutral safety switch is defective. 6. If engine does not crank in step 4, starter relay is defective. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Testing and Inspection Starter Solenoid: Testing and Inspection Starter Solenoid Test 1. Connect heavy jumper wire on starter relay between battery and solenoid terminals. If engine cranks, perform starter relay test. 2. If engine does not crank or solenoid chatters, check wiring and connectors from relay to starter for loose or corroded connections. 3. Repeat test and, if engine still does not crank properly, repair or replace starter as necessary. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations Door Lock And Power Window Circuit Breaker And Relays Location The circuit breaker is located behind the dash panel, in cavity # 10 of the fuse block. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 3719 Circuit Breaker: Testing and Inspection Door Lock And Power Window Circuit Breaker And Relays Location To test the circuit breaker, connect the negative lead of a voltmeter to a known good ground, and touch the positive lead to one terminal of the circuit breaker. If battery voltage is present, test the other terminal of the circuit breaker. If battery voltage is present on only one terminal, then the circuit breaker is defective. If battery voltage is present on neither terminal, check for a burned fusible link or power lead wire to the circuit breaker. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 3720 Circuit Breaker: Service and Repair Door Lock And Power Window Circuit Breaker And Relays Location Remove the four screws that attach the lower steering column cover to the dash panel. Locate the circuit breaker in cavity # 10 and pull it out. Use a test light check for power in cavity # 10. Power should be present only on one terminal. Install the new circuit breaker by pushing it in slowly, making certain that both terminals hold snugly. Power should now be present at both terminals. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Testing and Inspection Fuse: Testing and Inspection Door Lock And Power Window Circuit Breaker And Relays Location To test the circuit breaker, connect the negative lead of a voltmeter to a known good ground, and touch the positive lead to one terminal of the circuit breaker. If battery voltage is present, test the other terminal of the circuit breaker. If battery voltage is present on only one terminal, then the circuit breaker is defective. If battery voltage is present on neither terminal, check for a burned fusible link or power lead wire to the circuit breaker. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Testing and Inspection > Page 3724 Fuse: Service and Repair Circuit Breaker/Fuse Replacement Door Lock And Power Window Circuit Breaker And Relays Location Remove the four screws that attach the lower steering column cover to the dash panel. Locate the circuit breaker in cavity # 10 and pull it out. Use a test light check for power in cavity # 10. Power should be present only on one terminal. Install the new circuit breaker by pushing it in slowly, making certain that both terminals hold snugly. Power should now be present at both terminals. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3729 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3730 Fig. 1 Fuse Panel. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams Fig. 2 Bulkhead Connector. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations Door Lock And Power Window Circuit Breaker And Relays Location The circuit breaker is located behind the dash panel, in cavity # 10 of the fuse block. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 3738 Circuit Breaker: Testing and Inspection Door Lock And Power Window Circuit Breaker And Relays Location To test the circuit breaker, connect the negative lead of a voltmeter to a known good ground, and touch the positive lead to one terminal of the circuit breaker. If battery voltage is present, test the other terminal of the circuit breaker. If battery voltage is present on only one terminal, then the circuit breaker is defective. If battery voltage is present on neither terminal, check for a burned fusible link or power lead wire to the circuit breaker. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 3739 Circuit Breaker: Service and Repair Door Lock And Power Window Circuit Breaker And Relays Location Remove the four screws that attach the lower steering column cover to the dash panel. Locate the circuit breaker in cavity # 10 and pull it out. Use a test light check for power in cavity # 10. Power should be present only on one terminal. Install the new circuit breaker by pushing it in slowly, making certain that both terminals hold snugly. Power should now be present at both terminals. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Testing and Inspection Fuse: Testing and Inspection Door Lock And Power Window Circuit Breaker And Relays Location To test the circuit breaker, connect the negative lead of a voltmeter to a known good ground, and touch the positive lead to one terminal of the circuit breaker. If battery voltage is present, test the other terminal of the circuit breaker. If battery voltage is present on only one terminal, then the circuit breaker is defective. If battery voltage is present on neither terminal, check for a burned fusible link or power lead wire to the circuit breaker. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Testing and Inspection > Page 3743 Fuse: Service and Repair Circuit Breaker/Fuse Replacement Door Lock And Power Window Circuit Breaker And Relays Location Remove the four screws that attach the lower steering column cover to the dash panel. Locate the circuit breaker in cavity # 10 and pull it out. Use a test light check for power in cavity # 10. Power should be present only on one terminal. Install the new circuit breaker by pushing it in slowly, making certain that both terminals hold snugly. Power should now be present at both terminals. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3748 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 3749 Fig. 1 Fuse Panel. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams Fig. 2 Bulkhead Connector. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 3757 Alignment: Service and Repair Fig. 7 Alignment adjustment locations & directions. Cam bolt type Fig. 8 Alignment adjustment locations & directions. Pivot bolt type CASTER & CAMBER, ADJUST Independent Front Suspension Front suspension height must be checked and corrected as necessary prior to checking wheel alignment. 1. Remove all foreign material from exposed threads of cam adjusting bolt nuts or pivot bar adjusting bolt nuts. 2. Record initial camber and caster readings before loosening cam bolt nuts or pivot bar bolt nuts. 3. On vehicles using cam bolts, the camber and caster is adjusted by loosening the cam bolt nuts and turning the cam bolts as necessary until the desired setting is obtained. On vehicles using pivot bars, tool C-4581 or equivalent is required to adjust caster and camber. When performing adjustments, the camber settings should be held as close as possible to the "desired" setting, and the caster setting should be held as nearly equal as possible on both wheels. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 3758 Fig. 9 Caster angle adjustment. Exc. independent front suspension Exc. Independent Front Suspension No adjustment is provided for camber. If camber is not within specifications, axle or steering knuckle is bent and should be replaced. Caster may be adjusted by inserting a wedge between the spring and axle. To increase caster insert wedge so that the thick part faces rear of vehicle. To decrease caster insert wedge so that the thick end is toward front of vehicle. TOE-IN, ADJUST With the front wheels in straight ahead position, loosen the clamps at each end of both adjusting tubes. Adjust toe-in by turning the tie rod sleeve which will "center" the steering wheel spokes. If the steering wheel was centered, make the toe-in adjustment by turning both sleeves an equal amount. Position sleeve clamps so ends do not align in the sleeve slot. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul Power Steering Pump: Service and Repair Power Steering Pump Overhaul Disassembly Fig. 1 Vane type power steering pump w/integral reservoir disassembled (typical) Fig. 2 Removing end plate retaining ring Fig. 3 Removing flow control valve & spring Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 3765 Fig. 4 Thrust plate & rotor installed on driveshaft 1. Carefully mount pump in vise with soft jaws and remove reservoir cap. When clamping pump in vise, do not exert excessive force on front hub as this may distort drive shaft bushing in housing. 2. Remove rear pump mounting stud and Of-ring seal, pressure union and Of-ring seal. 3. Remove reservoir, and second pressure union Of-ring seal. 4. Using a small punch, depress end plate retaining ring enough to allow removal from groove. Use the 1/8 inch diameter hole in housing. Then remove retaining ring with screwdriver. 5. Remove end plate which is spring loaded and usually sits above housing level. If end plate sticks, a slight rocking action should free it. If rocking action fails to free plate, use a magnet. 6. Remove two pressure springs from pump housing. 7. Remove flow control valve and spring by inverting housing. Do not disassemble flow control valve as it is serviced as a unit and pre-set at the factory. 8. Remove drive shaft key from slot in shaft. Then with end of shaft pointed downward, press down until shaft is free. 9. Turn assembly over and remove drive shaft and rotary group. 10. Remove rotor retaining ring from groove in drive shaft. Remove rotor and thrust plate from shaft. 11. Remove and discard Of-ring seals from pump housing. Remove driveshaft oil seal only if inspection shows necessity for replacement. Inspection 1. Clean all parts except the drive shaft oil seal in cleaning fluid. The seal will be damaged if immersed in cleaning fluid. 2. Check fit of vanes in slots of rotor for tightness or excessive looseness. Vanes must fit snugly but slide freely in slots in rotor. Tight fit of vanes in rotor can usually be corrected by thorough cleaning. Replace rotor if excessive looseness exists between rotor and vanes. Replace vanes if worn or scored. 3. Examine machined surfaces of pump ring for roughness or wear. Replace ring if roughness cannot be corrected with crocus cloth. 4. Inspect thrust plate, pressure plate and end plate for wear, scores or other damage. 5. Inspect pump housing for cracks or damage. Check housing for evidence of wear or scoring. 6. Check all springs for free length, distortion or collapsed coils. 7. Inspect located dowel pins for distortion. 8. Examine outer diameter of flow control valve for scoring or roughness. Slight damage may be cleaned up with crocus cloth. Check valve assembly for freedom of movement in bore of pump housing. 9. Check all oil passages in pump parts for obstruction. Use a piece of tag wire to clean out holes. 10. Check bushing in pump housing for wear or damage. Assembly Fig. 4 Thrust plate & rotor installed on driveshaft Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 3766 Fig. 5 Installing driveshaft assembly Fig. 6 Installing pump ring Fig. 7 Installing rotor vanes 1. Lubricate new Of-ring seals with Vaseline and place in pump housing. 2. If drive shaft oil seal was removed during disassembly, lubricate new seal with Vaseline. Then install seal in pump body front hub, using a suitable seal driver. 3. Position thrust plate and rotor on drive shaft. Then install rotor retaining ring in groove of drive shaft. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 3767 4. Place pump housing on work bench as shown and install two pump ring dowel pins in bore of housing. 5. Install drive shaft in housing, making sure shaft seats properly. 6. Install pump ring in housing over two dowel pins with rotation arrow on ring to rear of pump housing.Arrow on outer edge of pump ring points in direction of pump rotation (counterclockwise when viewed from rear of pump). 7. Install rotor vanes in slots of pump rotor, with radius edge of vanes toward outside of rotor. Fig. 8 Installing pressure plate Fig. 9 Installing pressure plate springs 8. Position pump housing on two wood blocks and push parts down into place as shown. 9. Lubricate outside diameter and chamfer of pressure plate with Vaseline to insure against damage to Of-ring seals in housing. Then install pressure plate in housing over dowel pins.Ported face of pressure plate goes toward pump ring. 10. Using a 2 3/4 inch diameter sleeve to apply pressure to outer edge of pressure plate only, press pressure plate into seat. Pressure plate will travel about 1/16 inch to seat. Do not press or hammer on center of pressure plate as to do so will cause permanent distortion resulting in pump failure. 11. Install two pressure plate springs, one over each dowel pin in pump housing. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 3768 Fig. 10 Installing end plate & retaining ring Fig. 11 Installing flow control valve & spring Fig. 12 Installing pressure union O-ring seal 12. Lubricate outside diameter and chamfer of end plate with Vaseline to insure against damage to Of-ring seal in housing. Then press end plate into housing. While holding end plate down in housing, install end plate retaining ring. Be sure end plate is completely and solidly seated in groove of housing. 13. Remove assembly from press and place on work bench. Install flow control spring and valve in bore of housing. Make sure hex head screw goes into housing bore. 14. Position pressure union Of-ring seal in bore of housing over flow control valve. 15. Mount pump housing in vise with soft jaws and install reservoir. 16. Install pressure union and new O-ring seal in reservoir. Tighten union. 17. Install mounting stud and new O-ring seal in reservoir. Tighten stud. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 3769 18. Install drive shaft key in slot in shaft. Support shaft on opposite side while installing key. Install reservoir cap. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Overhaul > Page 3770 Power Steering Pump: Service and Repair Power Steering Pump Removal and Installation 1. Loosen pump locking and attaching bolts, then remove drive belt. 2. Disconnect both fluid hoses from pump. 3. Remove pump locking and attaching bolts, then remove pump and bracket assembly. 4. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3776 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 3777 Fig. 8 Cargo, Dome & Map Lamps Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation > Manual Steering Gear Steering Gear: Description and Operation Manual Steering Gear Fig. 1 Sectional view of Saginaw recirculating ball-worm & nut steering gear Fig. 2 Cross-sectional view of Saginaw recirculating ball-worm & nut gear As shown, the wormshaft on the lower end of the steering shaft and the ball nut which is mounted on the worm have mating spiral grooves in which steel balls circulate to provide a low friction drive between wormshaft and ball nut. Two sets of balls are used, ranging in number from approximately 20 to 30 to a set, depending upon the size of the gear unit. Each set of balls operate independently of the other. The circuit through which each set of balls circulates includes the grooves in the worm and ball nut and a ball return guide attached to the outer surface of the nut. When the wheel and steering shaft turn to the left, the ball nut is moved downward by the balls which roll between the worm and nut. As the balls Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation > Manual Steering Gear > Page 3782 reach the outer surface of the nut, they enter the return guides which direct them across and down into the ball nut where they enter the circuit again. When a right turn is made, the ball nut moves upward and the balls circulate in the reverse direction. The teeth of the ball nut engage teeth on the sector which is forged integral with the pitman shaft. The teeth on the ball nut are made so that a "high point" or tighter fit exists between the ball nut and pitman shaft sector teeth when the front wheels are in the straight-ahead position. The teeth on the sector are tapered slightly so that a proper lash may be obtained by moving the pitman shaft endwise by means of a lash adjuster screw which extends through the gear housing side cover. The head of the last adjuster and the selectively fitted shim fit snugly into a T-slot in the end of the pitman shaft so that the screw also controls end play of the shaft. The screw is locked by an external lock nut. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation > Manual Steering Gear > Page 3783 Steering Gear: Description and Operation Power Steering Gear Constant Control Type Power Steering Gear The Constant Control Full Time Power Steering consists of a hydraulic pressure pump, a power steering gear and connecting hoses. The power steering gear consists of a gear housing, containing a gear shaft and sector shaft, a power piston with gear teeth milled into the side of the piston which is in constant mesh with the gear shaft sector teeth, and a worm shaft which connects the steering wheel to the power unit piston through a coupling. The worm shaft is geared to the piston through recirculating ball contact, and the steering valve which is mounted on top of the steering gear directs system fluid flow. Saginaw Rotary Valve Power Gears Fig. 1 Steering gear identification Fig. 2 Model 800-808 Saginaw steering gear Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation > Manual Steering Gear > Page 3784 Fig. 3 Model 800-808 power steering gear disassembled Fig. 4 Model 605 power steering gear disassembled There are two types of Saginaw integral rotary valve type single piston steering gears. The two different types of gears can be identified by the configuration of the side covers. The Model 605 gear has a round side cover, secured with a retaining ring. The Model 800-808 gear has a rectangular side cover, secured with four bolts. Also, note that the Model 800-808 gear incorporates balls in the rack piston, while the Model 605 gear does not. The power steering gear operates entirely by displacing oil to provide hydraulic pressure assists only when turning. As the entire gear assembly is always filled with oil, all internal components of the gear are immersed in oil, making periodic lubrication unnecessary. In addition this oil acts as a cushion to absorb road shocks that may be transmitted to the driver. The steering shaft, hydraulic valve, worm and rack piston nut are all in line, making a compact and space saving steering gear. All oil passages are internal except the pressure and return hoses between gear and pump. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation > Page 3785 Steering Gear: Testing and Inspection Fig. 10 Adjusting steering gear mesh 1. Fill reservoir to level mark. 2. Connect test hoses to hydraulic pump on car with pressure gauge installed between pump and steering gear to register pressures. 3. Start engine and operate at idle to bring steering gear to normal operating temperature. 4. Center the valve until unit is not self steering. Tap valve body retaining screw heads to move valve body up on steering housing, or tap end plug to move valve body down. 5. Rotate worm shaft through range of travel to bleed air from system, then refill reservoir. 6. With steering gear on center, tighten sector shaft adjusting screw until backlash is removed from steering arm. If the power train was removed, tighten adjusting screw an additional 11/4 turns, then tighten locknut. 7. Operate unit through several cycles, aligning piston rack and sector teeth. 8. With gear on center, readjust sector shaft backlash. Loosen adjusting screw until backlash is present, then tighten adjusting screw until backlash is removed. Tighten adjusting screw an additional 3/8 to 1/2 turn and torque lock nut to 28 ft lb 9. Ensure torque at sector shaft required to turn unit through center at 2 RPM in each direction, starting from a point at least one full turn of the worm shaft to either side of center does not exceed 20 ft lb or vary more than 5 ft lb from left to right. Adjust valve to equalize torque in both directions, then torque valve body adjusting screw to 200 inch lbs. 10. With gear fully deflected in either direction, attempt to center unit by applying torque torque wrench at steering gear shaft. Hold worm shaft until sector shaft torque reaches 50 ft lb, then release worm shaft and maintain a steady pull at 2 RPM on the gear shaft. If sector shaft torque does not drop to 20 ft lb or less at the unit passes through center, check for excessive internal drag, binding spool valve or tight sector shaft adjustment. 11. Ensure, with unit under power and no load applied, torque required to rotate worm shaft 90 degrees to either side of center at 6 RPM is 6 - 10 inch lbs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Adjustments > Constant Control Type Power Steering Gears Steering Gear: Adjustments Constant Control Type Power Steering Gears Fig. 10 Adjusting steering gear mesh 1. Fill reservoir to level mark. 2. Connect test hoses to hydraulic pump on car with pressure gauge installed between pump and steering gear to register pressures. 3. Start engine and operate at idle to bring steering gear to normal operating temperature. 4. Center the valve until unit is not self steering. Tap valve body retaining screw heads to move valve body up on steering housing, or tap end plug to move valve body down. 5. Rotate worm shaft through range of travel to bleed air from system, then refill reservoir. 6. With steering gear on center, tighten sector shaft adjusting screw until backlash is removed from steering arm. If the power train was removed, tighten adjusting screw an additional 11/4 turns, then tighten locknut. 7. Operate unit through several cycles, aligning piston rack and sector teeth. 8. With gear on center, readjust sector shaft backlash. Loosen adjusting screw until backlash is present, then tighten adjusting screw until backlash is removed. Tighten adjusting screw an additional 3/8 to 1/2 turn and torque lock nut to 28 ft lb 9. Ensure torque at sector shaft required to turn unit through center at 2 RPM in each direction, starting from a point at least one full turn of the worm shaft to either side of center does not exceed 20 ft lb or vary more than 5 ft lb from left to right. Adjust valve to equalize torque in both directions, then torque valve body adjusting screw to 200 inch lbs. 10. With gear fully deflected in either direction, attempt to center unit by applying torque torque wrench at steering gear shaft. Hold worm shaft until sector shaft torque reaches 50 ft lb, then release worm shaft and maintain a steady pull at 2 RPM on the gear shaft. If sector shaft torque does not drop to 20 ft lb or less at the unit passes through center, check for excessive internal drag, binding spool valve or tight sector shaft adjustment. 11. Ensure, with unit under power and no load applied, torque required to rotate worm shaft 90 degrees to either side of center at 6 RPM is 6 - 10 inch lbs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Adjustments > Constant Control Type Power Steering Gears > Page 3788 Steering Gear: Adjustments Manual Steering Gear There are two adjustments on the steering gear: worn bearing preload and pitman shaft overcenter preload. Prior to adjusting the steering gear, all outside loads must be removed. Fig. 3 Steering gear adjustments Fig. 4 Checking adjustment with an inch pound torque wrench WORM BEARING PRELOAD, ADJUST 1. Disconnect battery ground cable, then raise and support vehicle. 2. Remove pitman arm nut, then mark relationship of pitman arm to pitman shaft to aid during reassembly. 3. Remove pitman arm using a suitable puller. 4. Loosen steering gear adjuster plug lock nut, then back off adjuster plug 1/4 turn. 5. Remove horn pad or button to gain access to the steering wheel attaching nut. 6. Turn steering wheel gently in one direction to stop, then turn back 1/2 turn to position steering gear away from "high point" load position. Do not turn wheel hard against steering stops with pitman arm disconnected as damage to the gear ball guides can result. 7. Position suitable inch pound torque wrench on steering wheel hub nut, then while rotating steering wheel with inch pound wrench through a 90 degree arc, record and measure "bearing drag." Do not use an inch pound wrench of more than 50 inch pound capacity. 8. Adjust worm bearing preload to specifications listed at end of section by turning adjuster plug while measuring turning torque at steering wheel hub with inch pound wrench. Worm bearing preload specification is in excess of "bearing drag" determined in previous step. 9. Torque adjuster plug lock nut to 25 ft lb, then recheck preload. Rotate steering wheel from stop to stop. If steering gear feels "lumpy", bearing damage is indicated. Gear should be disassembled and inspected as necessary. PITMAN SHAFT OVERCENTER PRELOAD, ADJUST 1. Perform steps 1 through 9 of "Worm Bearing Preload, Adjust" procedure. 2. Turn steering wheel from one stop to the other while carefully counting the total turns required, then turn wheel back exactly halfway to position steering gear at "high point." 3. Loosen lash adjuster screw lock nut, then turn adjuster screw clockwise to remove gear lash between ball nut and pinion shaft. Tighten lock nut. 4. Check steering wheel turning torque with suitable inch pound wrench at steering wheel hub, and compare to specifications listed at end of section. 5. If measurement is not within specifications, loosen lock nut and readjust adjuster screw to obtain proper turning torque. Tighten lock nut and check turning torque through center of steering wheel travel. If maximum turning torque exceeds specifications, turn adjuster screw counterclockwise, then come up on adjustment by turning in a clockwise direction. 6. Assemble pitman arm to pitman shaft. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Adjustments > Constant Control Type Power Steering Gears > Page 3789 Steering Gear: Adjustments Power Steering Gear Model 605 Bench Adjustments Fig. 29 Thrust bearing preload adjustment THRUST BEARING PRELOAD 1. Tighten adjuster plug until bottomed and torque to 30 ft lb. 2. Draw a line on gear housing and plug, and a second line 1/2 inch counter clockwise on housing only. 3. Turn adjuster back until mark on adjuster aligns with second mark on housing, then tighten lock nut. Fig. 30 Over-center preload adjustment OVER-CENTER PRELOAD 1. Back off preload adjuster until it stops, then turn in one turn.Preload adjuster has left hand thread. 2. Rotate stub shaft from stop to stop, counting number of turns, then back exactly 1/2 number of turns to locate center of travel. 3. Using an inch pound torque wrench, measure torque required to rotate stub shaft. Then turn adjuster until rotating torque is increased 6 to 10 inch lbs. Torque adjuster lock nut to 20 ft lb. Model 800-808 Bench Adjustments Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Adjustments > Constant Control Type Power Steering Gears > Page 3790 Fig. 29 Thrust bearing preload adjustment THRUST BEARING PRELOAD 1. Tighten adjuster plug until bottomed and torque to 20 ft lb. 2. Draw a line on gear housing and adjuster plug, and a second line 1/2 inch counter clockwise on housing only. 3. Turn adjuster plug counterclockwise until mark on adjuster aligns with second mark on housing. Tighten locknut while holding plug securely to prevent rotation. Fig. 31 On-bench over-center preload specification chart Fig. 32 Adjusting over-center preload OVER-CENTER PRELOAD 1. Rotate stub shaft from stop to stop, counting number of turns, then turn back exactly 1/2 number of turns to locate center of travel. 2. Measure combined ball and thrust bearing preload using an inch pound torque wrench to rotate stub shaft through the over center position. 3. Tighten adjusting screw while rotating stub shaft with torque wrench until torque reading obtained is specified inch pounds greater than combined ball and thrust bearing preload. Note that total steering gear preload must not exceed specifications. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service Steering Gear: Service and Repair Manual Steering Gear Service Fig. 5 Steering gear (typical) disassembled DISASSEMBLY 1. Loosen adjusting screw lock nut and remove housing side cover by removing adjusting screw. 2. Loosen lock nut and back off worm bearing adjuster several turns, then remove housing end cover and gasket. 3. Remove lower thrust bearing, steering shaft and upper bearing from housing. 4. Remove ball return guide clamps and guides from ball nut. Turn ball nut over and remove ball nut from steering shaft worm. INSPECTION OF COMPONENTS 1. Clean and inspect all ball and roller bearings and races, including race in housing. 2. Inspect pitman shaft bushings in gear housing and end cover. If bushings are worn excessively, replace bushings. 3. It is advisable to replace pitman shaft grease seal in housing to avoid possible leakage of lubricant. Seal must be installed with feather edge toward inside of housing. 4. Inspect pitman shaft for wear or pits in bearing races, which would require replacement of shaft. 5. Check shaft for straightness. 6. Inspect teeth of ball nut and pitman shaft. If scored or excessively worn it is advisable to replace both parts to insure proper mating of teeth. 7. Check serrations of pitman shaft; if twisted replace shaft. 8. Check fit of pitman shaft adjusting screw and shim in slot in end of pitman shaft. With shim in place, screw head must be free to turn in slot with zero to 0.002 inch end play. If end play is excessive, selectively fit a new shim, which are available in four different thicknesses. ASSEMBLY Lubricate all seals, bushings, bearings and gears with multi-purpose gear lube prior to installation. 1. Position ball nut over worm shaft so that deep side of teeth will be toward side cover when installed in gear housing. 2. Install exactly 1/2 the number of balls in each circuit, rocking worm shaft slightly to aid in installing balls. 3. Place about six balls in each return guide, using grease to hold balls in place. 4. Install return guides, clamp and screw. 5. Rotate worm through its complete travel several times to be sure balls are installed correctly and rotate freely. 6. Place upper bearing on worm shaft and slide worm shaft assembly into housing. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3793 7. Place lower bearing in worm bearing adjuster and install bearing retainer. 8. Install adjuster assembly and lock nut in housing. Tighten adjuster only enough to hold worm bearings in place. Final adjustment will be made later. 9. Turn worm shaft until center groove in ball nut lines up with center of pitman shaft bushing. 10. Install pitman shaft and lash adjuster with shim so that center tooth meshes with center groove in ball nut. 11. Install side cover with gasket on lash adjuster by turning adjuster counterclockwise. 12. Install side cover bolts and washers. 13. Turn lash adjuster so that teeth on shaft and ball nut engage but do not bind. 14. Install lash adjuster lock nut loosely. 15. To protect pitman shaft seal from damage, cover shaft splines with masking tape. Slide new seal into place and seat it against shoulder in housing. 16. Install new worm shaft seal flush with surface of housing. 17. Fill gear housing with multi-purpose lubricant and adjust gear assembly as outlined previously. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3794 Steering Gear: Service and Repair Power Steering Gear Service Constant Control Type Power Steering Gears Fig. 1 Valve body assembly removal Fig. 2 Pivot lever removal 1. Drain steering gear by rotating worm shaft from stop to stop. 2. Remove valve body attaching screws, then the valve body. Remove and discard three valve body O-rings. 3. Remove pivot lever and pivot lever spring by prying under spherical head of lever with a suitable screwdriver. Use care not to collapse slotted end of pivot lever, as this will destroy spherical head bearing tolerances. 4. Loosen sector shaft adjusting screw locknut, then remove sector shaft cover spanner nut using tool No. C-3989. 5. Install tool No. C-3786 onto threaded end of sector shaft, then slide tool into housing until tool and shaft engage with bearings. 6. Rotate wormshaft to full left turn position to compress power train components, then remove power train attaching nut using tool No. C-3989. Remove housing head washer. 7. While maintaining power train in a firmly compressed position, pry on piston teeth using a suitable screwdriver and remove complete power train. The cylinder head, center race and spacer assembly and the housing head must be kept in close contact since the reaction rings may become disengaged from grooves in cylinder head and housing. Also, the center spacer may separate from center race and jam in the housing, in turn damaging the spacer and/or housing when removing the power train. Saginaw Rack & Pinion Power Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3795 Fig. 1 Exploded view of Saginaw power rack & pinion steering gear Fig. 2 Removing tie rod from rack assembly 1. Mark position of tie rod end on tie rod, then loosen jam nut and remove tie rod end. 2. Remove jam nut, then using pliers to expand outer bellows clamp, remove clamp from bellows. An outer clamp is not used on 1983 vehicles. To prevent damage to the bellows when removing it, note the following. Slide the small end of the bellows towards the rack until the groove is exposed. Place a small rubber band in the groove, then slide the small end of the boot over the rubber band and off the threaded end of the tie rod. 3. Cut inner bellows clamp, then remove clamp from gear. 4. Mark breather tube location, then remove bellows from gear housing. 5. Remove shock dampener ring from tie rod housing and slide ring back on rack. 6. Using a wrench to prevent rack from turning, place a wrench on tie rod housing flats and turn housing counterclockwise until tie rod assembly separated from rack. 7. Loosen adjuster plug locknut, then turn adjuster plug counterclockwise to remove plug from housing. Remove spring and rack bearing from Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3796 housing bore. 8. Remove retaining ring from stub shaft. 9. Remove pinion shaft locknut dust cover. 10. While holding stub shaft in place, remove locknut from pinion shaft. If stub shaft is not held in place while removing locknut, damage to pinion teeth may result. 11. If only stub shaft seals are to be replaced, using a press, press on threaded end of stub shaft until shaft is flush with ball bearing assembly. Complete removal of valve and pinion assembly is not necessary to replace stub shaft seals. 12. To remove valve and pinion assembly, rotate stub shaft until rack is centered in housing, with pinion fully engaged. Mark position of stub shaft flat on housing for reassembly. Using a press, press on threaded end on pinion shaft until it is possible to remove valve and pinion shaft assembly. 13. If necessary, remove valve body seal rings. 14. Insert a suitable punch into access hole and remove bulkhead retaining ring. 15. If only bulkhead, bulkhead Of-ring seal or bulkhead rack seal are to be replaced, remove cylinder lines and plug both cylinder line holes in cylinder using two M12 x 1.25 bolts, tighten bolts finger tight. Position drain pan under gear, then rotate stub shaft to move rack toward right stop to force bulkhead out of housing. If inner rack seal or piston ring are to be replaced the rack must be removed from the housing. 16. Remove rack from housing, then remove piston ring from rack. Fig. 3 Removing inner rack seal Fig. 4 Removing pinion lower bearing Fig. 5 Removing & installing upper pinion bushing & seal 17. Remove inner rack seal from housing using tool L-4627. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3797 18. Remove lower pinion bearing retaining ring, then using a suitable drift, tap lower pinion bearing from housing. 19. Using a suitable drift, tap upper pinion bushing and seal from housing. 20. Using a suitable flare wrench, loosen fittings and remove cylinder lines from housing. Also remove line fitting Of-rings. 21. Mark breather tube location on housing for reassembly, then remove breather tube and grommet. Disassemble Gear Fig. 3 Model 800-808 power steering gear disassembled Fig. 5 Removing end plug retaining ring Fig. 6 Installing rack-piston arbor tool in end of worm Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3798 Fig. 7 Removing adjuster plug 1. Position gear in vise with gear housing end plug facing up. 2. Rotate gear housing end plug retaining ring so that one end of ring is over hole in housing. Spring one end of ring with a punch to allow screwdriver to be inserted to lift ring out. 3. Rotate coupling flange counterclockwise until rack-piston just forces end plug out of housing. Remove plug from housing. Do not rotate any further than necessary or balls fall out of their circuit and pitman shaft teeth and rack-piston will become disengaged. 4. Remove rack-piston end plug, using a 1/2 inch square drive.To make removal easier, tap rack-piston end plug with a plastic mallet to unseat threads. This is important as end plug is tightened to 75 - 80 ft-lbs during assembly and could break during removal if not handled carefully. 5. Remove lock nut from pitman shaft adjuster screw and discard. 6. Remove four side cover retaining screws and washers from cover. 7. Rotate pitman shaft adjuster screw with an Allen wrench until side cover is lifted free of housing. 8. Separate side cover from pitman shaft; discard side cover O-ring seal. 9. Turn coupling flange until pitman shaft teeth are centered in housing. 10. Tap end of pitman shaft with a soft mallet and slide pitman shaft out of housing. 11. Remove housing end plug O-ring seal and discard. 12. Insert Rack-Piston Arbor into rack-piston against end of worm. Turn coupling flange counterclockwise, while holding tool tightly against worm, to force rack-piston onto arbor, and remove rack-piston from gear housing. 13. Remove stub shaft-to-coupling flange retaining screw and remove flange. 14. Remove adjuster plug lock nut by breaking it loose with hammer and punch, and remove lock nut from housing. 15. Loosen adjuster plug and remove from housing. 16. Remove valve assembly by grasping stub shaft and pulling out. 17. Remove worm, lower thrust bearing and races from upper end of housing. Disassemble Housing 1. Remove pitman, shaft outer dust seal retaining ring. 2. Remove outer dust seal. 3. Remove seal (double lip) by inserting offset screwdriver between seal and back-up washer and prying out of housing. 4. Remove back-up washer. 5. Remove seal (single lip) by cutting and collaPSIng seal. 6. Remove pitman shaft needle bearings (if necessary) with a suitable driver. 7. If connectors are to be removed, tap threads in holes of connectors using 5/16-18 NF tap. Remove connectors by using threaded bolt into tapped holes with washer and nut as extractor. Stub Shaft & Spool Valve Removal Fig. 13 Valve & worm removed from rack.Model 605 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3799 Fig. 14 Valve & worm disassembled. Model 605 Fig. 15 Spool valve assembly. Model 605 Fig. 16 Stub shaft removal. Model 605 1. Remove valve and worm from rack, then the teflon ring and O-ring seal from rack piston. 2. Remove snap ring and worm shaft from valve. 3. To disassemble spool valve proceed as follows: a. Hold valve and tap stub shaft on wooden block to loosen shaft cap. b. To remove stub shaft, pull cap out 1/4 inch, then disengage pin on shaft from hole in spool. c. Rotate and lift spool from valve body. d. Remove teflon rings and O-rings from valve body and spool. Stub Shaft & Spool Valve Disassembly Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3800 Fig. 8 Rotary valve components 1. If used, work spool spring onto bearing diameter of stub shaft and remove spool spring. 2. Tap end of stub shaft gently against workbench to remove valve spool. Because of the slight clearance between valve body and spool, the slightest cocking of spool may jam it in valve body. If slight cocking occurs, make a gentle attempt to reverse removal procedure. If this does not free spool, it has become cocked in valve body bore and may be removed later. 3. Remove and discard valve spool dampener O-ring. 4. Remove stub shaft, torsion bar (small diameter bar extending through stub shaft) and valve cap by tapping end of torsion bar lightly with a plastic hammer. This will dislodge cap from valve body cap pin. Do not disassemble stub shaft as these parts are pinned together and serviced only as an assembly. 5. If valve spool has become cocked as mentioned above, first inspect parts to determine in which direction the spool is cocked. A few very light taps with a plastic hammer should align and free the spool in the bore. Remove and discard O-ring dampener seal from spool. 6. Carefully remove valve body Teflon rings and ring back-up O-ring seals. Gear Piston & Valve Assembly Removal Fig. 9 Lower thrust bearing & adjuster assembly. Model 605 Fig. 10 Stub shaft seals & snap ring. Model 605 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3801 Fig. 11 Stub shaft bearing removal. Model 605 Fig. 12 Pitman shaft seals & bearings. Model 605 1. Remove preload adjuster nut. Preload adjusting nut has a left hand thread. 2. Center gear by rotating stub shaft, then remove side cover snap ring, pitman shaft, side cover, O-ring seal and spring. 3. Remove locknut, adjuster plug and O-ring seal, then the lower thrust bearing assembly. 4. Push stub shaft to remove rack piston and valve assembly. 5. Remove stub shaft snap ring, dust seal and shaft seal, then the needle bearing and upper thrust bearing, if necessary. 6. Remove pitman shaft snap ring, dust seal, washer and oil seal, then the needle bearing, if necessary. Replacing Valve Spool Dampener O-Ring (Only If Gear Squawks) Fig. 8 Rotary valve components The rotary valve assembly includes the valve body, valve spool and stub shaft assembly. All these parts are precision units and are hydraulically balanced at the factory. Under no circumstances are parts in this unit to be replaced or interchanged with other parts or units. If unit parts are scored or Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3802 damaged the entire rotary valve assembly is to be replaced. The O-ring should be replaced only if the gear squawks. 1. To replace the valve spool dampener O-ring, work spool spring into bearing diameter of stub shaft and remove spool spring. 2. Tap end of stub shaft gently against workbench to remove valve spool. The diametrical clearance between the valve body and spool may be as low as 0.0004 inch. The slightest cocking of the spool may jam it in the valve body. 3. Remove valve spool dampener O-ring. 4. Install new O-ring in valve spool groove, then lubricate seal in automatic transmission fluid. Do not allow seal to twist in groove. 5. With notch end of spool towards valve body, install spool, aligning spool notch with pin in stub shaft. 6. Because of the small clearance between spool and valve body, extreme care must be taken when assembling these parts. Push spool evenly and slowly with a slight oscillating motion until spool reaches drive pin. Before pushing spool completely in, make sure dampener O-ring seal is evenly distributed in spool groove. Slowly push spool completely in, with extreme care taken not to cut or pinch O-ring seal. 7. Slide spool spring over stub shaft and work spring into position. Model 605 Rack Piston, Valve & Worm Fig. 14 Valve & worm disassembled. Model 605 Fig. 15 Spool valve assembly. Model 605 Fig. 21 Stub shaft installation. Model 605 1. To assemble spool valve proceed as follows: a. Install three teflon & three O-ring seals on spool. b. Lubricate spool with power steering fluid, then rotate spool while installing. c. Install stub shaft into valve body.Notch must fully engage pin and cap must seat against shoulder. 2. Assemble worm shaft on valve. Install snap ring with "curved-in end" on same side as access hole. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3803 Fig. 13 Valve & worm removed from rack.Model 605 Fig. 22 Installing valve & worm into rack.Model 605 Fig. 23 Stub shaft & rack positioning. Model 605 3. To install valve and worm in rack: a. Install teflon ring and O-ring seal. b. Hold rack teeth and worm drive pin in position. c. With light pressure to hold worm thread against piston, turn worm and valve counter-clockwise slowly until one click is felt, then turn clockwise to complete assembly. d. Check relation of stub shaft and rack piston by threading worm and valve into rack piston until valve face and rack piston face are flush. Flats on stub shaft and piston must be parallel. If not parallel, disassemble and repeat steps b and c. Model 605 Steering Gears Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3804 Fig. 12 Pitman shaft seals & bearings. Model 605 Fig. 27 Pitman shaft bearing installation. Model 605 1. If pitman shaft needle bearing was removed, install with lettered edge facing outward and flush with bottom of counter bore with a suitable tool. 2. Install pitman shaft oil seal, washer and snap ring. Fig. 9 Lower thrust bearing & adjuster assembly. Model 605 Fig. 10 Stub shaft seals & snap ring. Model 605 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3805 Fig. 28 Stub shaft bearing installation. Model 605 3. If removed, install stub shaft needle bearing and upper thrust bearing. 4. Apply anhydrous calcium grease to stub shaft seal, then install shaft seal, dust seal and snap ring. 5. Install rack piston and valve assembly, then lower thrust bearing, O-ring seal, adjuster plug and lock nut. See procedures for thrust bearing preload adjustment before tightening lock nut. 6. Install side cover spring and O-ring seal. 7. Install pitman shaft gear so center tooth of gear meshes with center groove of rack piston, then depress side cover and install snap ring. Open end of snap ring should be 1/2 inch from access hole. Assembly Notes Fig. 3 Model 800-808 power steering gear disassembled Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3806 Fig. 17 Adjuster plug components Lubricate all parts as they are assembled. 1. Screw lash adjuster through side cover until cover bottoms on pitman shaft gear. Install lash adjuster lock nut while holding lash adjuster with 7/32 inch Allen wrench. 2. Mount adjuster plug in vise with soft jaws. 3. If it has been removed, assemble needle bearing by pressing towards thrust bearing end of adjuster plug against identification end of bearing. End of bearing to be flush with bottom surface of stub shaft seal bore. 4. Install stub shaft far enough to provide clearance for dust seal and retaining ring. Install new dust seal with rubber surface outward. Install new retaining ring. 5. Assemble large thrust bearing race, thrust bearing, small race and spacer (with grooves up) on adjuster plug and secure with retainer. Assemble Housing Fig. 18 Pitman shaft seals & washers 1. With stamped end of needle bearing facing outward, drive bearing into bore from outside of housing until flush. Make sure bearings rotate freely. 2. Lubricate cavity between lips of pitman shaft (double lip) seal with power steering fluid. 3. Lubricate and install pitman shaft seals as shown. Make sure seal lips are properly positioned, retaining ring is seated. 4. If connectors were removed, install new ones by driving them into place. Assemble Rotary Valve 1. Assemble one valve body Teflon ring back-up O-ring seal in each groove in valve body, being sure seals do not become twisted. 2. Assemble valve Teflon rings in ring grooves over O-ring seals by carefully slipping rings over valve body. The rings may appear loose or twisted in the grooves but the heat of the oil during subsequent operation will cause them to straighten. 3. Install valve spool dampener O-ring seal in valve spool groove, being sure it is not twisted. 4. Insert stub shaft through valve spool, engaging spool locking pin. 5. Pull valve spool and stub shaft assembly into valve body, aligning stub shaft notch and valve body pin. 6. If used, slide spool spring over stub shaft and place into position. 7. Lubricate cap-to-worm O-ring and install in valve body. During assembly of the valve, if the stub shaft and cap is allowed to slip out of engagement with the valve body pin, the spool will be permitted to enter the valve body too far. The dampener O-ring seal may expand into valve body oil grooves, preventing removal of spool. If this happens, remove spool spring and disassemble rotary valve. Press on spool until O-ring seal is cut and can be removed. Install new O-ring and reassemble. Assemble Rack-Piston Worm & Valve Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3807 Fig. 24 Worm shaft & rotary valve components Fig. 25 Installing adjuster plug Fig. 26 Installing rack-piston seal compressor 1. Install valve and worm in housing as a unit. 2. Install new O-rings on adjuster plug. 3. Install adjuster plug on stub shaft in gear housing finger tight. 4. Holding a suitable Teflon ring compressor sleeve tightly against shoulder of gear housing, insert rack-piston nut and arbor into housing, holding arbor unit it contacts worm end. 5. Holding arbor tight against worm, turn stub shaft flange and worm to draw ball nut onto worm and into housing until arbor is free. Be certain that no balls drop out. 6. Remove arbor and sleeve. Check Worm Preload Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3808 Fig. 20 Checking worm preload The worm groove is ground with a high point in the center. When the rack-piston nut passes over this high point, a preload of a 1 to 4 inch pounds torque should be obtained. 1. With worm pointing up, clamp rack-piston nut in a vise with soft jaws (do not hold rack-piston nut in area of Teflon ring). 2. Place valve on worm, engaging worm drive pin. 3. Rotate worm until it extends 11/4 inch from rack-piston nut to thrust bearing face. This is the center position. 4. Attach an inch pound torque wrench with socket on stub shaft. Oscillate wrench through a total arc of approximately 60° in both directions several times and take a reading. The highest reading obtained with worm rotating should be between 1 and 4 inch pounds. Take a torque reading pulling the torque wrench to the right and a reading pulling the wrench to the left. Total both readings and take one half of this total as the average torque. Do not use a torque wrench having maximum torque reading of more than 100 inch pounds. Install Housing Lower End Plug 1. Install new housing end plug O-ring seal. 2. Insert end plug into gear housing and seat against O-ring. Slight pressure may be necessary to seat end plug properly. 3. Install end plug retainer ring so end of ring extends over and at least 1/2 inch beyond ring removal assist hole. Install Pitman Shaft Gear & Side Cover 1. Install stub shaft flange and turn steering worm until center groove of rack-piston is aligned with center of pitman shaft needle bearings. 2. Install new side cover O-ring. 3. Install pitman shaft gear so that center tooth of gear meshes with center groove of rack-piston. Make sure side cover O-ring is in place before pushing cover against housing. 4. Install and tighten side cover screws. Install Rack-Piston Nut End Plug 1. Install new O-ring seal on end plug, being careful not to allow seal to twist in groove. 2. Install end plug into rack-piston nut by pressing into place. 3. Install end plug retaining ring, being sure ring is bottomed in its groove. Install Rack-Piston Worm & Valve Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3809 Fig. 19 Loading rack-piston nut 1. Lubricate and install new ring back-up seal and Teflon piston ring on rack-piston nut, being careful ring and seal do not twist during installation. 2. Insert worm into rack-piston nut to bearing shoulder. 3. Align ball return guide holes with worm groove. Load balls into guide hole nearest the teflon piston ring while slowly rotating worm to left, feeding balls through circuit. If balls are installed properly, the worm should turn out of the rack-piston nut. 4. Fill one-half of ball return guide with remaining balls. Place other guide over balls and plug each end with heavy grease to prevent balls from falling out when installing guides into rack-piston nut. 5. Insert guides into guide holes of rack-piston nut. Make sure black ball in guide is installed next to white ball in rack piston. Guides should fit loosely. Install Stub Shaft Flange Rotate stub shaft slightly over two complete turns from either extreme right or left turn. This will place gear in center position, which will place torsion bar pin through stub shaft in a straight up and down position. Rotate flange so the bolt with the large head is in top position. Visually align the block tooth in the serrations of the flange with the torsion bar pin and install flange on stub shaft. Tighten flange clamping bolt. Refitting Rack-Piston Balls Do not refit balls unless the steering is loose. If such is the case, a thrust adjustment and over-center adjustment should correct the problem if it lies in the steering gear. If balls are pitted or rough, then select the proper ball size for proper adjustment. If the torque reading obtained above is too high or too low (on new balls only), disassemble and reassemble, using the next size smaller (or larger) balls and recheck worm preload. A rack-piston nut with a ball size of 7 does not have a number stamped on the flat surface. For ball sizes other than 7, the ball size is stamped on the flat surface of the rack-piston nut. Ball sizes are numbered from 6 to 11, with 6 being the smallest and 11 the largest. Ball sizes are graduated in increments of 0.00008 inch from 0.28117 inch to 0.28157 inch. Sub-Assemblies, Install Fig. 25 Installing adjuster plug Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3810 Fig. 26 Installing rack-piston seal compressor 1. Position gear housing in vise with adjuster plug end facing up. 2. Lubricate worm shaft, lower thrust bearing and races with power steering fluid, then position thrust bearing and race on worm. 3. Align valve body drive pin on worm with narrow pin slot on valve body. Be sure O-ring seal between valve body and worm head is installed. 4. Position valve body and worm shaft in housing as a unit. Do not push against stub shaft as this might cause stub shaft and cap to pull out of valve body, allowing spool seal to slip into valve body oil grooves. Valve assembly can be installed by pushing on outer diameter of valve body housing with the fingers of both hands. Make certain that Teflon rings are not binding on inside of housing. Valve is properly seated when oil return hole in gear housing is fully visible. 5. Place a suitable seal protector over end of stub shaft. 6. Lubricate new adjuster plug O-ring seal with power steering fluid and install in groove on adjuster plug. 7. Install adjuster plug over end of stubshaft and tighten just enough to make certain that all parts are properly seated in gear housing. Remove seal protector. 8. Install adjuster plug lock nut loosely on adjuster plug. 9. Install seal compressor in gear housing, holding it tightly against shoulder in housing. 10. Insert rack-piston into housing until arbor engages worm. Turn stub shaft clockwise, using a suitable wrench to draw rack-piston into housing. When piston ring is in housing bore, arbor and seal compressor can be removed. 11. Turn stub shaft as necessary until middle rack groove in rack-piston is aligned with center of pitman shaft needle bearing. 12. Lubricate new side cover O-ring seal and install in groove in face of side cover. 13. Assemble side cover on pitman shaft by screwing cover onto adjusting screw until cover bottoms on pitman shaft. 14. Install pitman shaft so that center tooth in sector meshes with center groove of rack-piston. Make sure side cover O-ring is in place before pushing side cover down on gear housing. 15. Install side cover screws and lockwashers. 16. Hold adjuster screw with Allen wrench and install new adjuster lock nut halfway on adjuster screw. 17. Install rack-piston end plug in rack-piston and tighten plug to 75 - 80 ft lb. 18. Lubricate new housing end plug O-ring seal with power steering fluid and install in gear housing. 19. Insert end plug into gear housing and seat against O-seal. Slight tapping with a mallet may be necessary to seat end plug properly. 20. Snap end plug retainer ring into place with fingers. Slight tapping may be required to bottom ring in housing securely. Install coupling flange. Constant Control Type Gears Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3811 Fig. 3 Power train removal 1. With steering gear housing fastened in holding fixture, lubricate power train housing bore with fluid and install power train assembly. Face piston teeth to the right and valve lever hole in center race and spacer in "Up" position. Ensure cylinder head is bottomed against housing shoulder. 2. With valve lever hole in center bearing race and spacer aligned with valve level hole in gear housing, install valve lever (double bearing end first) into center bearing race and spacer, ensuring valve lever slots are parallel to worm shaft. It may be necessary to gently tap end of valve lever to seat lower pivot point in center race. 3. Install housing head tang washer, indexing with groove in housing, and steering column support nut, and torque nut to 150 - 200 ft lb. Ensure valve lever remains centered in housing hole by rotating worm shaft until piston bottoms in both directions and observe valve lever action. The valve lever must be in center of hole and return to the center position when worm shaft torque is relieved. 4. Install valve lever spring (small end first), position power piston at center of travel and install sector shaft and cover assembly, indexing sector teeth with piston rack teeth. Ensure sector shaft cover O-ring is installed properly. 5. Install and torque cover nut to 110 - 200 ft lb. 6. Install valve body onto housing with valve lever entering hole in valve spool. Ensure O-rings are installed properly, then install and torque valve retaining screws to 7 ft lb. Powertrain Assembly Service Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3812 Fig. 4 Exploded view of Chrysler Constant Control power steering gear Fig. 5 Reaction seal removal Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3813 Fig. 6 Cylinder head oil seal ring removal DISASSEMBLE 1. Place powertrain vertically in a suitable soft jawed vise to prevent damage to piston assembly. To retain 33 worm bearing needle roller bearing during housing head removal, use arbor tool No. C-3929. 2. Raise housing head until worm shaft oil seal clears top of worm shaft, then position tool No. C-3929 on top of worm shaft and into seal. Raise housing head until arbor is positioned in bearing, then remove housing head and arbor. bearings become dislodged during head removal, retain in housing head using a suitable grease for installation. If necessary to replace worm shaft oil seal, perform operation with housing head installed in gear housing. 3. Remove large O-ring from housing head, then the reaction seal from groove in housing head face by forcing compressed air into ferrule chamber. 4. Remove reaction spring, reaction ring, worm balancing ring and spacer, then retain worm shaft rotation and remove nut from knurled section. 5. Remove thin upper bearing race, then the thrust bearing. 6. Remove center bearing race, then the lower thrust bearing and thick race. 7. Remove lower reaction ring and spring, then the cylinder head assembly. 8. Remove two cylinder head outer groove O-rings, then the reaction O-ring from groove in face of cylinder head by forcing compressed air into oil hole located between the two O-ring grooves. Remove snap ring and seal. 9. Remove snap ring, sleeve and rectangular oil seal ring from cylinder head counterbore. 10. Ensure torque required to rotate worm shaft throughout its full travel in or out of piston does not exceed 1.5 inch lbs. The worm and piston assembly are serviced as a complete unit and should not be disassembled. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3814 Fig. 4 Exploded view of Chrysler Constant Control power steering gear ASSEMBLE 1. Seat piston ring in its groove by pressing down on piston, opening the ends for proper locking action. 2. Vertically position piston assembly (worm shaft side up) in a suitable soft jawed vise, then lubricate two large O-rings with a suitable lubricant. Install O-rings into cylinder head grooves. 3. Install worm sleeve seal, sleeve and snap ring, if removed, then install lower reaction O-ring seal in cylinder head groove. 4. Slide cylinder head assembly ferrule side up on worm shaft, then inspect worm shaft seal ring to ensure gap is closed to avoid ring damage as cylinder head contacts piston flange. 5. Lubricate the following parts with a suitable power steering fluid, then install in order as follows: a. Thick lower thrust bearing race. b. Lower thrust bearing. c. Lower reaction spring, ensuring small hole is over ferrule. d. Lower reaction ring with flange up so ring protrudes through reaction spring and contacts O-ring in cylinder head. e. Center bearing race. f. Upper thrust bearing. g. Thin upper thrust bearing race. h. New worm shaft thrust bearing adjusting nut (do not tighten). 6. Rotate worm shaft clockwise 1/2 turn, then retain worm shaft in position with splined nut, tool No. C-3637 and a suitable socket wrench. 7. Torque adjusting nut to 50 ft lb to pre-stretch worm shaft threads. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3815 Fig. 7 Center bearing preload check Fig. 8 Staking worm shaft bearing adjustment nut Fig. 9 Installing reaction seal & O-ring 8. With worm shaft in retained position as described in step 6, loosen adjusting nut, then place several rounds of cord around center bearing race. Make a loop in one end of cord, then attach a spring scale to loop. Pull cord using spring scale, which will cause bearing race to rotate. Tighten worm bearing adjusting nut while pulling on scale until a reading of 16 to 24 ounces is obtained while race is turning. 9. With worm shaft in retained position as described in step 6, stake upper part of worm shaft adjusting nut into knurled area of shaft, then hold a 1/4 inch flat end punch on center line of worm shaft end at a slight angle. Strike punch, then check preload. If adjusting nut moved during staking operation, correct by striking with a glancing blow in direction required to regain proper preload. If proper preload was obtained, stake locknut in three more locations 90° apart. Test for proper staking by applying 20 ft lb of torque in each direction on locknut. If movement does not occur, staking is satisfactory. 10. Position spacer assembly over center race, engaging race slot with dowel pin and spacer slot over cylinder head ferrule. Ensure valve lever hole in center bearing race is aligned with center spacer. 11. Install upper reaction ring on center race, then the spacer with flange down against spacer. 12. Install upper reaction spring over reaction ring with cylinder head ferrule through hole in reaction spring. 13. Install worm balancing ring inside upper reaction ring without flange, then apply a suitable lubricant to ferrule O-ring and insert into groove on cylinder head ferrule. 14. If oil seal was removed from housing head, install new seal using tool No. C-3650, ensuring lip of oil seal faces bearing and seal is driven inward until tool bottoms on support. 15. Apply a suitable lubricant to reaction seal, then insert into groove on face of housing head with flat side of seal out. Install housing head O-ring. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3816 16. Slide housing head over worm shaft, engaging cylinder head ferrule and O-ring and ensuring reaction rings enter circular grooves in housing head. Constant Control Type Power Steering Gear Repairs Prior to disassembly, clean the gear assembly thoroughly in a suitable solvent. Crocus cloth may be used to remove small nicks and burrs provided it is used carefully. When used on the steering gear valve, use extreme care not to round off the sharp edge portions of the two lands located between the valve drilled holes. Remove and discard all O-ring seals, using new ones lubricated with fluid when reassembling. Steering Gear Housing Prior to disassembly, clean the gear assembly thoroughly in a suitable solvent. Crocus cloth may be used to remove small nicks and burrs provided it is used carefully. When used on the steering gear valve, use extreme care not to round off the sharp edge portions of the two lands located between the valve drilled holes. Remove and discard all O-ring seals, using new ones lubricated with fluid when reassembling. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3817 Steering Gear: Service and Repair Steering Gear Replacement Manual Steering Gear Replacement 1980-81 TRAIL DUSTER & 1980-87 RAMCHARGER & CONVENTIONAL CAB 1. Disconnect battery ground cable. 2. Remove two wormshaft coupling attaching bolts. 3. Remove steering arm from steering gear using tool No. C-4150. 4. Remove steering gear to frame attaching bolts, then the gear from vehicle. 5. Reverse procedure to install. Power Steering Gear Replacement EXC. VANS, WAGONS & FRONT SECTIONS 1. Center steering gear. 2. Remove steering gear arm to shaft attaching bolt, then the steering gear arm using suitable tool. 3. Disconnect power steering hoses at gear. Cap all hoses and fluid ports to prevent oil leakage. 4. Disconnect shaft coupling from steering gear. 5. Remove steering gear to frame attaching bolts, then the gear from vehicle. On some Motor Homes, body location may require steering gear and bracket be removed as an assembly. If gear and bracket is removed as an assembly, support assembly with suitable transmission jack and remove frame to bracket attaching bolts. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 3818 Steering Gear: Service and Repair Saginaw Rotary Valve Power Steering Gears Four factors affect power operation of the steering system: fluid level and condition, drive belt tension, pump pressure and steering gear adjustment. These should always be checked before any major service operations are performed. Conditions such as, hard or loose steering, road shock or vibrations are not always due to steering gear or pump, but are often related instead to such factors as low tire pressure and front end alignment. These factors should be checked and corrected before any adjustment of the steering gear is made. CHECKING FLUID LEVEL 1. Run engine to normal operating temperature, then shut it off. Remove reservoir filler cap and check oil level on dipstick. Level should be up to "Full" mark on dipstick. 2. If level is low, add power steering fluid to proper level on dipstick and replace filler cap. When adding less than one pint of fluid, it is permissible to use automatic transmission fluid. When adding larger quantities or when making a complete fluid change, it is recommended that special power steering fluid be used. 3. When checking fluid level after system has been serviced, air must be bled from the system as outlined under "Bleeding System." BLEEDING SYSTEM 1. With wheels turned all the way to the left, add the recommended fluid to the "Add" mark on dipstick. 2. Start engine. While running at fast idle, recheck fluid level and, if necessary, add fluid to the "Add" mark on dipstick. 3. Bleed system by turning wheels from side to side without hitting stops. Maintain fluid level just above internal pump casting. Fluid with air in it will have a light tan appearance. This air must be eliminated from fluid before normal steering action can be obtained. 4. Return wheels to center position and continue to run engine for two or three minutes, then shut it off. 5. Road test vehicle to make sure steering functions normally and is free from noise. 6. Recheck fluid level, making sure level is at the "Full" mark. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Technical Service Bulletins > Steering Column - Coupler Service Steering Shaft Coupler: Technical Service Bulletins Steering Column - Coupler Service NO.: 19-03-93 GROUP: Steering DATE: Apr. 16, 1993 SUBJECT: Steering Column Coupler Service MODELS: 1979-1993 (AD) Ram Pickup/Ram Cab Chassis/Ramcharger DISCUSSION: A new repair package with a revised boot design has been developed to service the steering coupler on the intermediate steering column. If the steering coupler requires service, the new repair package should be used. PARTS REQUIRED: 1 Repair Package - Steering Coupler 4740761 REPAIR PROCEDURE: This bulletin involves release of a new repair package for the steering coupler with a revised boot design. 1. Remove and discard the existing cover and seal. 2. Disassemble the coupler and inspect the shoes, shoe retaining spring, internal bearing surfaces of the coupler body, and the shaft pin for evidence of wear. Replace any worn components. 3. Fill the coupler body 1/2 full with Multipurpose Grease, NGLI Grade 2 EP, such as MOPAR P/N 4318062 or equivalent. 4. Place the boot and clamp on the shaft. 5. Press the shoe pin onto the steering shaft so that it projects equal distance on the shaft. 6. Place the spring on the side of the shaft, straddling the shoe pin. 7. Place the shoes on the pin ends with the flat side towards the spring, engaging the tangs. 8. Squeeze the shoes together, compressing the spring, and push the assembly into the coupler body with the master spline on the upper shaft. 9. Drive in the NEW dowel pin flush with the outer surface of the coupler body. 10. Position the boot on the body and install the clamps on both ends. Be sure that the contact surfaces are free of grease. 11. Work the shaft in and out several times to distribute the grease in the assembly. POLICY: Information Only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Replacement Ball Joint: Service and Repair Lower Ball Joint Replacement EXC. 4 WHEEL DRIVE Upper Ball Joint 1. Place ignition switch in the "Off" position. 2. Using a suitable jack raise front of vehicle and position a jack stand under lower control arm as close to wheel and tire assembly as possible. 3. Remove wheel and tire assembly. 4. Remove cotter pin and nut from upper ball joint stud. Position tool No. C3564-A or equivalent over lower ball joint stud, allowing tool to rest on knuckle arm, then set tool securely against upper ball joint stud. 5. Tighten tool to apply pressure against upper ball joint stud, then strike knuckle with hammer to loosen stud. 6. Remove tool, then detach upper ball joint from knuckle. Support knuckle and brake assembly to prevent damage to lower ball joint and brake hoses. 7. Remove upper ball joint from upper control arm, using tool No. C3561. 8. Reverse procedure to install. Thread upper ball joint into control arm as far as possible by hand. Torque upper ball joint into control arm to 125 ft lb Install ball joint into steering knuckle, then torque attaching bolts to 135 ft lb Ball joint seals should be replaced whenever they have been removed. Lower Ball Joint 1. Remove coil spring, refer to "Coil Spring, Replace" procedure. 2. Remove ball joint seal, then press ball joint out of lower control arm using tool No. C-4212 or equivalent. 3. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Replacement > Page 3828 Ball Joint: Service and Repair Upper Ball Joint Replacement EXC. 4 WHEEL DRIVE Upper Ball Joint 1. Place ignition switch in the "Off" position. 2. Using a suitable jack raise front of vehicle and position a jack stand under lower control arm as close to wheel and tire assembly as possible. 3. Remove wheel and tire assembly. 4. Remove cotter pin and nut from upper ball joint stud. Position tool No. C3564-A or equivalent over lower ball joint stud, allowing tool to rest on knuckle arm, then set tool securely against upper ball joint stud. 5. Tighten tool to apply pressure against upper ball joint stud, then strike knuckle with hammer to loosen stud. 6. Remove tool, then detach upper ball joint from knuckle. Support knuckle and brake assembly to prevent damage to lower ball joint and brake hoses. 7. Remove upper ball joint from upper control arm, using tool No. C3561. 8. Reverse procedure to install. Thread upper ball joint into control arm as far as possible by hand. Torque upper ball joint into control arm to 125 ft lb. Install ball joint into steering knuckle, then torque attaching bolts to 135 ft lb. Ball joint seals should be replaced whenever they have been removed. Lower Ball Joint 1. Remove coil spring, refer to "Coil Spring, Replace" procedure. 2. Remove ball joint seal, then press ball joint out of lower control arm using tool No. C-4212 or equivalent. 3. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Stabilizer Bar Replacement Stabilizer Bar: Service and Repair Stabilizer Bar Replacement 1. Remove link rod attaching nut from each end of sway bar. 2. Remove retainers and rubber bushings from sway bar link rods. 3. Remove sway bar support bracket attaching bolts, then the sway bar. 4. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Stabilizer Bar Replacement > Page 3833 Stabilizer Bar: Service and Repair Front 1. Disconnect bar from right and left end links. 2. Disconnect attaching bolts from frame mounting brackets. 3. Remove bar assembly from vehicle. 4. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > Customer Interest for Suspension Spring ( Coil / Leaf ): > 020285 > Feb > 85 > Front Suspension - Vehicle Low On Left Front Corner Suspension Spring ( Coil / Leaf ): Customer Interest Front Suspension - Vehicle Low On Left Front Corner Models All Domestic Built Two Wheel Drive Pick-Up Trucks Subject Front Spring Spacer Index FRONT SUSPENSION Date February 4, 1985 No.. 02-02-85 P-378 SYMPTOM/CONDITION Vehicle leaning or low on the left front corner. PARTS REQUIRED 1 - Spring Spacer PN 4322629 REPAIR PROCEDURE Spring Spacer, PN 4322629, is now available to raise the left front corner by approximately one inch. The spacer is to be installed on the top of the coil spring. Refer to the appropriate service manual, Section 17 (Springs), for spring removal and installation. NOTE: ONLY ONE SPACER IS TO BE USED. DO NOT STACK. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 02-27-01-90 . . . . . . . . . . . . 1.0 Hrs. FAILURE CODE: 6X - Weak Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Spring ( Coil / Leaf ): > 020285 > Feb > 85 > Front Suspension - Vehicle Low On Left Front Corner Suspension Spring ( Coil / Leaf ): All Technical Service Bulletins Front Suspension - Vehicle Low On Left Front Corner Models All Domestic Built Two Wheel Drive Pick-Up Trucks Subject Front Spring Spacer Index FRONT SUSPENSION Date February 4, 1985 No.. 02-02-85 P-378 SYMPTOM/CONDITION Vehicle leaning or low on the left front corner. PARTS REQUIRED 1 - Spring Spacer PN 4322629 REPAIR PROCEDURE Spring Spacer, PN 4322629, is now available to raise the left front corner by approximately one inch. The spacer is to be installed on the top of the coil spring. Refer to the appropriate service manual, Section 17 (Springs), for spring removal and installation. NOTE: ONLY ONE SPACER IS TO BE USED. DO NOT STACK. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 02-27-01-90 . . . . . . . . . . . . 1.0 Hrs. FAILURE CODE: 6X - Weak Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Coil Spring Replace Suspension Spring ( Coil / Leaf ): Service and Repair Front Coil Spring Replace RAMCHARGER, TRAIL DUSTER & CONVENTIONAL CABS 1. Raise and support vehicle. 2. Remove front wheels, then the caliper retainer. 3. Remove caliper from disc and position caliper aside, then remove inboard shoe. Do not allow caliper to hang or be supported by hydraulic brake hose. 4. On 1980-84 models, proceed as follows: a. Remove grease cap, cotter key, locknut, adjusting nut, washer and outer bearing. b. Slide rotor from steering knuckle. Use caution not to damage steering knuckle thread, bearing or oil seal when removing rotor. c. Remove splash shield attaching screws, then the splash shield, if equipped. 5. On all models, remove shock absorber, then disconnect sway bar at link, if equipped. 6. Remove spring pin from strut, then loosen strut attaching nut. 7. Install spring compressor tool No. DD-1278 finger tight, then back off half turn. 8. Remove cotter keys and ball joint nuts. 9. Install ball joint breaker tool No. C-3564-A or equivalent over lower ball joint stud, then set tool securely against upper ball joint stud. 10. Tighten tool to apply pressure against upper ball joint stud, then strike knuckle with hammer to loosen stud. 11. Remove tool, then slowly loosen coil spring compressor until all tension is relieved from spring. 12. Remove spring compressor and spring. 13. Reverse procedure to install noting the following: a. Torque ball joint nuts to 135 ft lb. b. Torque sway bar attaching bolt to 100 in lb. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Coil Spring Replace > Page 3849 Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring Replacement Front MOTOR HOME & 4 WHEEL DRIVE MODELS 1. Raise vehicle until weight is removed from springs, then support spring using suitable jack. 2. Remove nuts, lock washers, U-bolts and U-bolt seat securing spring to axle. 3. Remove spring shackle attaching bolts, shackles and spring front eye bolt. 4. Remove spring from vehicle. 5. Reverse procedure to install. Rear RAMCHARGER, TRAIL DUSTER, CONVENTIONAL CAB & MOTOR HOME 1. Raise vehicle until weight is removed from springs and wheels are just touching ground, then support vehicle using suitable safety stands. 2. Remove nuts, lock washers and U-bolts attaching spring to axle. 3. Remove spring shackle attaching bolts, shackle and spring front bolt, then remove spring. 4. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Strut / Shock Absorber: Service and Repair Front 1. Raise and support vehicle. 2. Turn wheel as needed to gain access to upper shock absorber mount, then remove upper nut and retainer. 3. Remove two lower attaching bolts, then the shock. 4. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 3854 Suspension Strut / Shock Absorber: Service and Repair Rear MOTOR HOME 1. Remove shock absorber to frame attaching bolts. 2. Remove shock absorber lower bracket attaching nut, rubber bushing and washers. 3. Remove shock absorber and bracket assembly from vehicle, then the bracket from the shock. 4. Reverse procedure to install. RAMCHARGER, TRAIL DUSTER & CONVENTIONAL CAB 1. Remove two shock absorber bracket to frame attaching bolts. 2. On models equipped with 4 wheel drive, remove lower bracket attaching bolt, loosen upper attaching bolt, then rotate bracket until shock absorber clears upper bolt and remove. 3. On all models, remove shock absorber lower bracket attaching nut, rubber bushings and washers. 4. Remove shock absorber and bracket assembly from vehicle, then the bracket from the shock. 5. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments EXC. MOTOR HOME & 4 WHEEL DRIVE 1. Torque adjusting nut to 360-480 inch lbs. for Vans, Wagons and Front Sections or 90 inch lbs. for Ramcharger, Trail Duster and Conventional Cabs while rotating wheel. 2. Stop wheel from rotating, then back off adjusting nut to completely release bearing preload. 3. Tighten adjusting nut finger tight, then install locknut and cotter key. End play should be 0.0001 to 0.003 inch. 4. Clean grease cap, coat inside with suitable wheel bearing grease and install cap. Do not fill cap with grease. MOTOR HOME 1. Rotate wheel and tighten adjusting nut until a slight binding is felt. 2. Back off adjusting nut so that the nearest slot indexes with the cotter pin hole in the spindle. Never back off adjusting nut less than half the distance from one slot to the next slot. 3. Install cotter pin to locknut and ensure that wheel rotates freely. 4 WHEEL DRIVE SPICER 44FBJ & 44-8FD Axle 1. Raise and support vehicle. 2. Remove locking hub assembly, then the wheel bearing locknut and washer. 3. Torque adjusting nut to 50 ft. lbs., using tool No. C-4170 or equivalent, to seat the bearing. 4. Loosen adjusting nut and retorque to 30-40 ft. lbs. while rotating hub, then back off adjusting nut 135°-150°. 5. Install retaining washer and bearing locknut. Torque locknut to 50 ft. lbs. Endplay should be 0.001 to 0.010 inch. SPICER 60 Axle 1. Raise and support vehicle. 2. Remove hub cap, then the snap ring using suitable pliers. 3. Remove flange nuts and lock washers, then the drive flange or locking hub if equipped. 4. Straighten tang on lock ring, then using tool No. DD-1241-JD or equivalent, remove outer locknut and lock ring. 5. Torque locknut to 50 ft. lbs. to seat the bearing, loosen locknut and retorque to 30-40 ft. lbs. Back off locknut 135°-150°. 6. Install lock ring and outer locknut. Torque locknut to 65 ft. lbs. 7. Bend tangs of long ring over both locknuts. Endplay should be 0.001 to 0.010 inch. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments EXC. MOTOR HOME & 4 WHEEL DRIVE 1. Torque adjusting nut to 360-480 inch lbs. for Vans, Wagons and Front Sections or 90 inch lbs. for Ramcharger, Trail Duster and Conventional Cabs while rotating wheel. 2. Stop wheel from rotating, then back off adjusting nut to completely release bearing preload. 3. Tighten adjusting nut finger tight, then install locknut and cotter key. End play should be 0.0001 to 0.003 inch. 4. Clean grease cap, coat inside with suitable wheel bearing grease and install cap. Do not fill cap with grease. MOTOR HOME 1. Rotate wheel and tighten adjusting nut until a slight binding is felt. 2. Back off adjusting nut so that the nearest slot indexes with the cotter pin hole in the spindle. Never back off adjusting nut less than half the distance from one slot to the next slot. 3. Install cotter pin to locknut and ensure that wheel rotates freely. 4 WHEEL DRIVE SPICER 44FBJ & 44-8FD Axle 1. Raise and support vehicle. 2. Remove locking hub assembly, then the wheel bearing locknut and washer. 3. Torque adjusting nut to 50 ft. lbs., using tool No. C-4170 or equivalent, to seat the bearing. 4. Loosen adjusting nut and retorque to 30-40 ft. lbs. while rotating hub, then back off adjusting nut 135°-150°. 5. Install retaining washer and bearing locknut. Torque locknut to 50 ft. lbs. Endplay should be 0.001 to 0.010 inch. SPICER 60 Axle 1. Raise and support vehicle. 2. Remove hub cap, then the snap ring using suitable pliers. 3. Remove flange nuts and lock washers, then the drive flange or locking hub if equipped. 4. Straighten tang on lock ring, then using tool No. DD-1241-JD or equivalent, remove outer locknut and lock ring. 5. Torque locknut to 50 ft. lbs. to seat the bearing, loosen locknut and retorque to 30-40 ft. lbs. Back off locknut 135°-150°. 6. Install lock ring and outer locknut. Torque locknut to 65 ft. lbs. 7. Bend tangs of long ring over both locknuts. Endplay should be 0.001 to 0.010 inch. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Except Model 60 and 70 rear axles Coned nut with 1/2 x 20 thread ....................................................................................................................................................... 105 ft lb (142 Nm) Model 60 and 70 rear axles Coned nut with 5/8 x 18 thread ......................................................................................................................................... 175-225 ft lb (217-305 Nm) Flanged nut with 5/8 x 18 thread ...................................................................................................................................... 300-350 ft lb (407-475 Nm) Flanged nut with 1 1/8 x 16 thread ................................................................................................................................... 450-500 ft lb (610-678 Nm) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > With A/C Blower Motor: Locations With A/C Heater & A/C System Components RH Side Of Engine Compartment Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > With A/C > Page 3870 Blower Motor: Locations Without A/C Heater Without A/C RH Side Of Engine Compartment Applicable to: Models Less A/C Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 3871 Blower Motor: Service and Repair 1981-87 MODELS 1. Disconnect battery ground cable and blower motor wiring. 2. Remove screws holding blower motor to heater housing on firewall. 3. Remove blower. 4. Reverse procedure to install. Fig. 19 Heater assembly. 1981 Trail Duster & 1981-87 Ramcharger & Conventional Cabs. With A/C 1981-87 MODELS 1. Disconnect battery ground cable and blower motor wiring. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 3872 2. Remove screws holding blower motor to heater housing on firewall. 3. Remove blower. 4. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > Customer Interest for Compressor Clutch: > 240286 > Jun > 86 > A/C Compressor Clutch - Repeat Failures Compressor Clutch: Customer Interest A/C Compressor Clutch - Repeat Failures Models 1985 & 1986 Domestic Vehicles Subject A/C Clutch Failure Index AIR CONDITIONING Date June 2, 1986 No. 24-02-86 P-2031 This bulletin is issued to clarify the application of the A/C clutch and pulley, and supply additional diagnostic information on A/C clutch failures. There are two types of clutches and pulleys available for service. The new style "stepped" pulley is to be used ONLY with the new style "stepped" clutch coil assembly. SYMPTOM/CONDITION Repeat failure of the air conditioning clutch and pulley assembly. The failure will appear to be a burned out condition that occurs for no apparent reason, after all specifications were correct at the time of installation. The clutch contact area will generally have a bluish or burned metal appearance, with no indication of compressor shaft seal oil leakage. CORRECTIVE ACTION Carefully inspect the FAILED pulley assembly prior to discarding it, to verify that it is either a "stepped" or "nonstepped" pulley assembly. If the pulley assembly is a "stepped" pulley, it should have had a "stepped" clutch coil assembly installed behind it. If inspection reveals that a "stepped" pulley assembly has been installed over a "non-stepped" clutch coil assembly, this is probably what caused the failure. The IMPROVED STEPPED CLUTCH AND COIL design was developed to increase the application pressure and reduce slipping of the A/C clutch when it is engaged. Using the "stepped" clutch assembly with the "non-stepped" clutch coil reduces the clutch apply pressure which causes the assembly to fail. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > Customer Interest for Compressor Clutch: > 240286 > Jun > 86 > A/C Compressor Clutch - Repeat Failures > Page 3882 FIGURE 1 The "non-stepped" pulley assembly will NOT fit over the "stepped" coil assembly; however, the "stepped" pulley assembly WILL fit over the "nonstepped" coil assembly. DO NOT USE THE "STEPPED" PULLEY ASSEMBLY IN COMBINATION WITH THE "NON-STEPPED" CLUTCH COIL ASSEMBLY (FIGURE 1). A/C CLUTCH FAILURE DIAGNOSIS A/C Clutch Noisy 1. Using your hands or suitable tool between the front of the compressor and the clutch coil assembly, determine if the coil assembly is loose. 2. If the clutch is loose, remove the assembly and determine that the snap ring was installed properly, and seated in the groove. 3. If the snap ring was installed correctly and the clutch assembly is still loose, check the alignment pin in the compressor. If the alignment pin hole in the coil assembly is elongated, or the pin is loose, replace the compressor front cover and the clutch/coil assemblies. 4. When installing the new parts, make sure that the snap ring is installed with the beveled edge facing out or away from the compressor. Positioning of the snap ring is important. Be sure that the "eyes" of the snap ring are NOT lined up with the coil retaining pin, they MUST be positioned either to the right or left of the pin. NOTE: BE SURE THE NEW COIL ASSEMBLY IS TIGHT TO THE COMPRESSOR. IF THE COIL IS LOOSE AT THE TIME OF INSTALLATION, ENGINE VIBRATIONS WILL CAUSE THE COMPRESSOR FRONT CASE TO WEAR AWAY AND THE CLUTCH FAILURE WILL REPEAT. A/C CLUTCH SLIPPING OR BURNED 1. Using Miller Tool C-4563 on the clutch pulley, rotate the compressor shaft. If the compressor will NOT rotate, it has seized, and will have to be Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > Customer Interest for Compressor Clutch: > 240286 > Jun > 86 > A/C Compressor Clutch - Repeat Failures > Page 3883 replaced. 2. If the compressor can be rotated, remove the pulley assembly and inspect the friction surfaces. 3. If the friction surfaces are oily, or show signs of contamination, inspect the compressor shaft seal area for a leak. Remove the "felt" from the nose of the compressor and inspect for oil. A small amount of oil on the back of the felt is acceptable. If the felt is saturated with oil, the shaft seal has failed and MUST BE REPLACED. 4. If the compressor shaft seal is OK, locate and correct the source of the oil contamination (compressor head bolt, front cover porosity, fuel pump gasket, valve cover gasket, refrigerant line, head gasket, etc.). 5. If the friction surfaces are dry, the coil is probably partially shorted and will have to be replaced. 2. Using a feeler gauge inserted between the front plate and the pulley face, measure the clearance. It should be 20-35 thousanths of an inch around the entire surface of the clutch. 3. If the clearance is NOT correct, it MUST be corrected by installing the proper shims between the coil assembly and the front plate. (Refer to the shop manual for shim installation.) A/C CLUTCH DOES NOT OPERATE 1. Connect a jumper from the battery to the clutch and check for operation. If the clutch does NOT operate, it is open circuit and will have to be replaced. 2. If the clutch DOES operate, check to see that the current draw does not exceed 5 amperes. If the current draw DOES exceed 5 amperes, the clutch is shorted and must be replaced. 3. Reconnect the clutch to the vehicle wiring, and install jumpers across the low pressure cut-out switch and the clutch cycling switch. 4. Push the A/C button and place the fan switch in "high blow." 5. Start the vehicle and allow for time delay. 6. If the clutch does NOT engage, check the system fuse, the push button switch, or the clutch/fan relay. 7. If the clutch does engage, remove the jumpers one at a time and reconnect the wiring to the switch. If the clutch disengages when the jumper is removed for the switch, the switch is defective and must be replaced. If the clutch engages with the low pressure cut-out switch jumpered, check for low charge and correct. If the charge is not low, replace the low pressure cut-out switch. NOTE: ANY TIME THE CLUTCH IS ENGAGED, THE A/C FAN MUST BE RUNNING. IF IT DOES NOT COME ON, THE FAN, FAN RELAY, OR WIRING ARE DEFECTIVE AND MUST BE CORRECTED. CLUTCH BURNISHING PROCEDURE After a new clutch and pulley assembly has been installed, cycle the clutch at least 20 cycles at 5 second intervals. For example: 5 seconds on, five seconds off 20 times. POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch: > 240286 > Jun > 86 > A/C Compressor Clutch - Repeat Failures Compressor Clutch: All Technical Service Bulletins A/C Compressor Clutch - Repeat Failures Models 1985 & 1986 Domestic Vehicles Subject A/C Clutch Failure Index AIR CONDITIONING Date June 2, 1986 No. 24-02-86 P-2031 This bulletin is issued to clarify the application of the A/C clutch and pulley, and supply additional diagnostic information on A/C clutch failures. There are two types of clutches and pulleys available for service. The new style "stepped" pulley is to be used ONLY with the new style "stepped" clutch coil assembly. SYMPTOM/CONDITION Repeat failure of the air conditioning clutch and pulley assembly. The failure will appear to be a burned out condition that occurs for no apparent reason, after all specifications were correct at the time of installation. The clutch contact area will generally have a bluish or burned metal appearance, with no indication of compressor shaft seal oil leakage. CORRECTIVE ACTION Carefully inspect the FAILED pulley assembly prior to discarding it, to verify that it is either a "stepped" or "nonstepped" pulley assembly. If the pulley assembly is a "stepped" pulley, it should have had a "stepped" clutch coil assembly installed behind it. If inspection reveals that a "stepped" pulley assembly has been installed over a "non-stepped" clutch coil assembly, this is probably what caused the failure. The IMPROVED STEPPED CLUTCH AND COIL design was developed to increase the application pressure and reduce slipping of the A/C clutch when it is engaged. Using the "stepped" clutch assembly with the "non-stepped" clutch coil reduces the clutch apply pressure which causes the assembly to fail. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch: > 240286 > Jun > 86 > A/C Compressor Clutch - Repeat Failures > Page 3889 FIGURE 1 The "non-stepped" pulley assembly will NOT fit over the "stepped" coil assembly; however, the "stepped" pulley assembly WILL fit over the "nonstepped" coil assembly. DO NOT USE THE "STEPPED" PULLEY ASSEMBLY IN COMBINATION WITH THE "NON-STEPPED" CLUTCH COIL ASSEMBLY (FIGURE 1). A/C CLUTCH FAILURE DIAGNOSIS A/C Clutch Noisy 1. Using your hands or suitable tool between the front of the compressor and the clutch coil assembly, determine if the coil assembly is loose. 2. If the clutch is loose, remove the assembly and determine that the snap ring was installed properly, and seated in the groove. 3. If the snap ring was installed correctly and the clutch assembly is still loose, check the alignment pin in the compressor. If the alignment pin hole in the coil assembly is elongated, or the pin is loose, replace the compressor front cover and the clutch/coil assemblies. 4. When installing the new parts, make sure that the snap ring is installed with the beveled edge facing out or away from the compressor. Positioning of the snap ring is important. Be sure that the "eyes" of the snap ring are NOT lined up with the coil retaining pin, they MUST be positioned either to the right or left of the pin. NOTE: BE SURE THE NEW COIL ASSEMBLY IS TIGHT TO THE COMPRESSOR. IF THE COIL IS LOOSE AT THE TIME OF INSTALLATION, ENGINE VIBRATIONS WILL CAUSE THE COMPRESSOR FRONT CASE TO WEAR AWAY AND THE CLUTCH FAILURE WILL REPEAT. A/C CLUTCH SLIPPING OR BURNED 1. Using Miller Tool C-4563 on the clutch pulley, rotate the compressor shaft. If the compressor will NOT rotate, it has seized, and will have to be Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Clutch: > 240286 > Jun > 86 > A/C Compressor Clutch - Repeat Failures > Page 3890 replaced. 2. If the compressor can be rotated, remove the pulley assembly and inspect the friction surfaces. 3. If the friction surfaces are oily, or show signs of contamination, inspect the compressor shaft seal area for a leak. Remove the "felt" from the nose of the compressor and inspect for oil. A small amount of oil on the back of the felt is acceptable. If the felt is saturated with oil, the shaft seal has failed and MUST BE REPLACED. 4. If the compressor shaft seal is OK, locate and correct the source of the oil contamination (compressor head bolt, front cover porosity, fuel pump gasket, valve cover gasket, refrigerant line, head gasket, etc.). 5. If the friction surfaces are dry, the coil is probably partially shorted and will have to be replaced. 2. Using a feeler gauge inserted between the front plate and the pulley face, measure the clearance. It should be 20-35 thousanths of an inch around the entire surface of the clutch. 3. If the clearance is NOT correct, it MUST be corrected by installing the proper shims between the coil assembly and the front plate. (Refer to the shop manual for shim installation.) A/C CLUTCH DOES NOT OPERATE 1. Connect a jumper from the battery to the clutch and check for operation. If the clutch does NOT operate, it is open circuit and will have to be replaced. 2. If the clutch DOES operate, check to see that the current draw does not exceed 5 amperes. If the current draw DOES exceed 5 amperes, the clutch is shorted and must be replaced. 3. Reconnect the clutch to the vehicle wiring, and install jumpers across the low pressure cut-out switch and the clutch cycling switch. 4. Push the A/C button and place the fan switch in "high blow." 5. Start the vehicle and allow for time delay. 6. If the clutch does NOT engage, check the system fuse, the push button switch, or the clutch/fan relay. 7. If the clutch does engage, remove the jumpers one at a time and reconnect the wiring to the switch. If the clutch disengages when the jumper is removed for the switch, the switch is defective and must be replaced. If the clutch engages with the low pressure cut-out switch jumpered, check for low charge and correct. If the charge is not low, replace the low pressure cut-out switch. NOTE: ANY TIME THE CLUTCH IS ENGAGED, THE A/C FAN MUST BE RUNNING. IF IT DOES NOT COME ON, THE FAN, FAN RELAY, OR WIRING ARE DEFECTIVE AND MUST BE CORRECTED. CLUTCH BURNISHING PROCEDURE After a new clutch and pulley assembly has been installed, cycle the clutch at least 20 cycles at 5 second intervals. For example: 5 seconds on, five seconds off 20 times. POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Technical Service Bulletins > Customer Interest for Compressor Pulley: > 240286 > Jun > 86 > A/C Compressor Clutch - Repeat Failures Compressor Pulley: Customer Interest A/C Compressor Clutch - Repeat Failures Models 1985 & 1986 Domestic Vehicles Subject A/C Clutch Failure Index AIR CONDITIONING Date June 2, 1986 No. 24-02-86 P-2031 This bulletin is issued to clarify the application of the A/C clutch and pulley, and supply additional diagnostic information on A/C clutch failures. There are two types of clutches and pulleys available for service. The new style "stepped" pulley is to be used ONLY with the new style "stepped" clutch coil assembly. SYMPTOM/CONDITION Repeat failure of the air conditioning clutch and pulley assembly. The failure will appear to be a burned out condition that occurs for no apparent reason, after all specifications were correct at the time of installation. The clutch contact area will generally have a bluish or burned metal appearance, with no indication of compressor shaft seal oil leakage. CORRECTIVE ACTION Carefully inspect the FAILED pulley assembly prior to discarding it, to verify that it is either a "stepped" or "nonstepped" pulley assembly. If the pulley assembly is a "stepped" pulley, it should have had a "stepped" clutch coil assembly installed behind it. If inspection reveals that a "stepped" pulley assembly has been installed over a "non-stepped" clutch coil assembly, this is probably what caused the failure. The IMPROVED STEPPED CLUTCH AND COIL design was developed to increase the application pressure and reduce slipping of the A/C clutch when it is engaged. Using the "stepped" clutch assembly with the "non-stepped" clutch coil reduces the clutch apply pressure which causes the assembly to fail. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Technical Service Bulletins > Customer Interest for Compressor Pulley: > 240286 > Jun > 86 > A/C Compressor Clutch - Repeat Failures > Page 3899 FIGURE 1 The "non-stepped" pulley assembly will NOT fit over the "stepped" coil assembly; however, the "stepped" pulley assembly WILL fit over the "nonstepped" coil assembly. DO NOT USE THE "STEPPED" PULLEY ASSEMBLY IN COMBINATION WITH THE "NON-STEPPED" CLUTCH COIL ASSEMBLY (FIGURE 1). A/C CLUTCH FAILURE DIAGNOSIS A/C Clutch Noisy 1. Using your hands or suitable tool between the front of the compressor and the clutch coil assembly, determine if the coil assembly is loose. 2. If the clutch is loose, remove the assembly and determine that the snap ring was installed properly, and seated in the groove. 3. If the snap ring was installed correctly and the clutch assembly is still loose, check the alignment pin in the compressor. If the alignment pin hole in the coil assembly is elongated, or the pin is loose, replace the compressor front cover and the clutch/coil assemblies. 4. When installing the new parts, make sure that the snap ring is installed with the beveled edge facing out or away from the compressor. Positioning of the snap ring is important. Be sure that the "eyes" of the snap ring are NOT lined up with the coil retaining pin, they MUST be positioned either to the right or left of the pin. NOTE: BE SURE THE NEW COIL ASSEMBLY IS TIGHT TO THE COMPRESSOR. IF THE COIL IS LOOSE AT THE TIME OF INSTALLATION, ENGINE VIBRATIONS WILL CAUSE THE COMPRESSOR FRONT CASE TO WEAR AWAY AND THE CLUTCH FAILURE WILL REPEAT. A/C CLUTCH SLIPPING OR BURNED 1. Using Miller Tool C-4563 on the clutch pulley, rotate the compressor shaft. If the compressor will NOT rotate, it has seized, and will have to be Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Technical Service Bulletins > Customer Interest for Compressor Pulley: > 240286 > Jun > 86 > A/C Compressor Clutch - Repeat Failures > Page 3900 replaced. 2. If the compressor can be rotated, remove the pulley assembly and inspect the friction surfaces. 3. If the friction surfaces are oily, or show signs of contamination, inspect the compressor shaft seal area for a leak. Remove the "felt" from the nose of the compressor and inspect for oil. A small amount of oil on the back of the felt is acceptable. If the felt is saturated with oil, the shaft seal has failed and MUST BE REPLACED. 4. If the compressor shaft seal is OK, locate and correct the source of the oil contamination (compressor head bolt, front cover porosity, fuel pump gasket, valve cover gasket, refrigerant line, head gasket, etc.). 5. If the friction surfaces are dry, the coil is probably partially shorted and will have to be replaced. 2. Using a feeler gauge inserted between the front plate and the pulley face, measure the clearance. It should be 20-35 thousanths of an inch around the entire surface of the clutch. 3. If the clearance is NOT correct, it MUST be corrected by installing the proper shims between the coil assembly and the front plate. (Refer to the shop manual for shim installation.) A/C CLUTCH DOES NOT OPERATE 1. Connect a jumper from the battery to the clutch and check for operation. If the clutch does NOT operate, it is open circuit and will have to be replaced. 2. If the clutch DOES operate, check to see that the current draw does not exceed 5 amperes. If the current draw DOES exceed 5 amperes, the clutch is shorted and must be replaced. 3. Reconnect the clutch to the vehicle wiring, and install jumpers across the low pressure cut-out switch and the clutch cycling switch. 4. Push the A/C button and place the fan switch in "high blow." 5. Start the vehicle and allow for time delay. 6. If the clutch does NOT engage, check the system fuse, the push button switch, or the clutch/fan relay. 7. If the clutch does engage, remove the jumpers one at a time and reconnect the wiring to the switch. If the clutch disengages when the jumper is removed for the switch, the switch is defective and must be replaced. If the clutch engages with the low pressure cut-out switch jumpered, check for low charge and correct. If the charge is not low, replace the low pressure cut-out switch. NOTE: ANY TIME THE CLUTCH IS ENGAGED, THE A/C FAN MUST BE RUNNING. IF IT DOES NOT COME ON, THE FAN, FAN RELAY, OR WIRING ARE DEFECTIVE AND MUST BE CORRECTED. CLUTCH BURNISHING PROCEDURE After a new clutch and pulley assembly has been installed, cycle the clutch at least 20 cycles at 5 second intervals. For example: 5 seconds on, five seconds off 20 times. POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Pulley: > 240286 > Jun > 86 > A/C Compressor Clutch - Repeat Failures Compressor Pulley: All Technical Service Bulletins A/C Compressor Clutch - Repeat Failures Models 1985 & 1986 Domestic Vehicles Subject A/C Clutch Failure Index AIR CONDITIONING Date June 2, 1986 No. 24-02-86 P-2031 This bulletin is issued to clarify the application of the A/C clutch and pulley, and supply additional diagnostic information on A/C clutch failures. There are two types of clutches and pulleys available for service. The new style "stepped" pulley is to be used ONLY with the new style "stepped" clutch coil assembly. SYMPTOM/CONDITION Repeat failure of the air conditioning clutch and pulley assembly. The failure will appear to be a burned out condition that occurs for no apparent reason, after all specifications were correct at the time of installation. The clutch contact area will generally have a bluish or burned metal appearance, with no indication of compressor shaft seal oil leakage. CORRECTIVE ACTION Carefully inspect the FAILED pulley assembly prior to discarding it, to verify that it is either a "stepped" or "nonstepped" pulley assembly. If the pulley assembly is a "stepped" pulley, it should have had a "stepped" clutch coil assembly installed behind it. If inspection reveals that a "stepped" pulley assembly has been installed over a "non-stepped" clutch coil assembly, this is probably what caused the failure. The IMPROVED STEPPED CLUTCH AND COIL design was developed to increase the application pressure and reduce slipping of the A/C clutch when it is engaged. Using the "stepped" clutch assembly with the "non-stepped" clutch coil reduces the clutch apply pressure which causes the assembly to fail. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Pulley: > 240286 > Jun > 86 > A/C Compressor Clutch - Repeat Failures > Page 3906 FIGURE 1 The "non-stepped" pulley assembly will NOT fit over the "stepped" coil assembly; however, the "stepped" pulley assembly WILL fit over the "nonstepped" coil assembly. DO NOT USE THE "STEPPED" PULLEY ASSEMBLY IN COMBINATION WITH THE "NON-STEPPED" CLUTCH COIL ASSEMBLY (FIGURE 1). A/C CLUTCH FAILURE DIAGNOSIS A/C Clutch Noisy 1. Using your hands or suitable tool between the front of the compressor and the clutch coil assembly, determine if the coil assembly is loose. 2. If the clutch is loose, remove the assembly and determine that the snap ring was installed properly, and seated in the groove. 3. If the snap ring was installed correctly and the clutch assembly is still loose, check the alignment pin in the compressor. If the alignment pin hole in the coil assembly is elongated, or the pin is loose, replace the compressor front cover and the clutch/coil assemblies. 4. When installing the new parts, make sure that the snap ring is installed with the beveled edge facing out or away from the compressor. Positioning of the snap ring is important. Be sure that the "eyes" of the snap ring are NOT lined up with the coil retaining pin, they MUST be positioned either to the right or left of the pin. NOTE: BE SURE THE NEW COIL ASSEMBLY IS TIGHT TO THE COMPRESSOR. IF THE COIL IS LOOSE AT THE TIME OF INSTALLATION, ENGINE VIBRATIONS WILL CAUSE THE COMPRESSOR FRONT CASE TO WEAR AWAY AND THE CLUTCH FAILURE WILL REPEAT. A/C CLUTCH SLIPPING OR BURNED 1. Using Miller Tool C-4563 on the clutch pulley, rotate the compressor shaft. If the compressor will NOT rotate, it has seized, and will have to be Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Pulley: > 240286 > Jun > 86 > A/C Compressor Clutch - Repeat Failures > Page 3907 replaced. 2. If the compressor can be rotated, remove the pulley assembly and inspect the friction surfaces. 3. If the friction surfaces are oily, or show signs of contamination, inspect the compressor shaft seal area for a leak. Remove the "felt" from the nose of the compressor and inspect for oil. A small amount of oil on the back of the felt is acceptable. If the felt is saturated with oil, the shaft seal has failed and MUST BE REPLACED. 4. If the compressor shaft seal is OK, locate and correct the source of the oil contamination (compressor head bolt, front cover porosity, fuel pump gasket, valve cover gasket, refrigerant line, head gasket, etc.). 5. If the friction surfaces are dry, the coil is probably partially shorted and will have to be replaced. 2. Using a feeler gauge inserted between the front plate and the pulley face, measure the clearance. It should be 20-35 thousanths of an inch around the entire surface of the clutch. 3. If the clearance is NOT correct, it MUST be corrected by installing the proper shims between the coil assembly and the front plate. (Refer to the shop manual for shim installation.) A/C CLUTCH DOES NOT OPERATE 1. Connect a jumper from the battery to the clutch and check for operation. If the clutch does NOT operate, it is open circuit and will have to be replaced. 2. If the clutch DOES operate, check to see that the current draw does not exceed 5 amperes. If the current draw DOES exceed 5 amperes, the clutch is shorted and must be replaced. 3. Reconnect the clutch to the vehicle wiring, and install jumpers across the low pressure cut-out switch and the clutch cycling switch. 4. Push the A/C button and place the fan switch in "high blow." 5. Start the vehicle and allow for time delay. 6. If the clutch does NOT engage, check the system fuse, the push button switch, or the clutch/fan relay. 7. If the clutch does engage, remove the jumpers one at a time and reconnect the wiring to the switch. If the clutch disengages when the jumper is removed for the switch, the switch is defective and must be replaced. If the clutch engages with the low pressure cut-out switch jumpered, check for low charge and correct. If the charge is not low, replace the low pressure cut-out switch. NOTE: ANY TIME THE CLUTCH IS ENGAGED, THE A/C FAN MUST BE RUNNING. IF IT DOES NOT COME ON, THE FAN, FAN RELAY, OR WIRING ARE DEFECTIVE AND MUST BE CORRECTED. CLUTCH BURNISHING PROCEDURE After a new clutch and pulley assembly has been installed, cycle the clutch at least 20 cycles at 5 second intervals. For example: 5 seconds on, five seconds off 20 times. POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair Heater Core: Service and Repair Fig. 17 Heater assembly. Ramcharger, Trail Duster & Conventional Cabs less A/C. 1981-84 shown, 1985-87 similar 1981-87 Models 1. Disconnect battery ground cable. 2. Disconnect heater hoses on engine side and plug heater outlets. 3. Remove right side cowl trim if so equipped. 4. Remove glove box, then structural brace through glove box opening. 5. Remove right half of instrument panel lower reinforcement, making sure to disconnect ground strap. 6. Disconnect control cables, then blower motor wires on engine side. 7. Disconnect wires from resistor block. 8. Remove screw holding heater to cowl side sheet metal. 9. Remove 6 heater retaining nuts on firewall, then remove heater. 10. Remove mode door crank and 15 screws to remove cover from housing, then slide heater core out. 11. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Page 3911 Fig. 19 Heater assembly. 1981 Trail Duster & 1981-87 Ramcharger & Conventional Cabs. With A/C 1981-87 Models 1. Disconnect battery ground cable. 2. Discharge A/C system and disconnect refrigerant and heater lines from unit. 3. Move shift levers away from dash. 4. Remove right side cowl trim panel, if equipped. 5. Remove 4 screws at base and remove glove box. 6. Remove brace through glove box opening and remove ashtray. 7. Remove right half of lower reinforcement (7 screws to instrument panel and 1 to cowl side of trim panel). 8. Disconnect radio ground strap. 9. Remove right upper air duct by removing mounting screw and pulling duct out through glove box opening. 10. Remove instrument panel center brace and right instrument panel cluster pivot bolt. 11. Remove instrument panel cluster, disconnect shift indicator cable and lower steering column. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Page 3912 12. Remove steering column studs and radio. 13. Remove scoop connecting heater to center distribution duct (2 screws). 14. Remove center distribution duct by pulling bottom of dash out to gain clearance. 15. Remove floor air distribution duct. 16. Disconnect temperature control cable through glove box. 17. Remove 7 retaining nuts from firewall and screw that retains assembly to cowl side sheet metal. 18. Flex dash out and remove heater assembly. 19. Remove nuts from door arms and remove door arms. 20. Remove 7 screws to remove cover from housing. 21. Remove evaporator core. 22. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts Technical Service Bulletin # 181986 Date: 860210 Choke - Hard Hot Restarts Models All 1985-1986 Cars & Trucks Equipped With Quadrajet 4-BBL Carburetors (318-360) Subject Premature Choke Closing Causing Hard Hot Restarts Index DRIVEABILITY Date February 10, 1986 No. 18-19-86 P-362-C Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Partial choke closure which results in a rich condition causing hard worm and hard hot starts in cool or cold ambients. The vehicle may exhibit block smoke out the tailpipe for the first few miles of driving. DIAGNOSIS Remove the air cleaner and visually verify the choke blade is closing when the engine is worm or hot while the ambient is cool or cold. PARTS REQUIRED For 318 4BBL Passenger Cars and 318/360 4BBL D and W Trucks Driveability PN 4397683 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose (Preformed) PN 4361146 1 Heater Hose PN 3849197 1 Screw PN 3730000 "M" body cars will require the following to be ordered separately: 1 Water Valve PN 4085474 3 Tie Wraps PN 6015756 For 318 4BBL Police Vehicles With Silicone Hoses Only Driveability Package PN 4397684 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose (Preformed Silicone) PN 3849564 1 Heater Hose Silicone PN 3849472 1 Water Valve PN 4085474 1 Screw PN 3730000 3 Tie Wraps PN 6015756 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 3921 For 318 4BBL/360 4BBL "B" Model Vans Driveability Package PN 4397685 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose PN 4361142 3 Tie Wraps PN 6015756 1 Screw PN 3730000 To be ordered separately for all vehicles: 1 Authorized Modification Label PN 4275086 Repair Procedures This repair procedure involves the routing of the heater supply hose so it contacts the choke housing. The heat from this hose reduces the tendency of the choke to close before the engine cools off. It is, therefore, very important the heater hose be in direct contact with the choke housing. "M" Body Passenger Cars and D-W Series Trucks Without Silicone Heater Hoses and With Air Conditioning 1. Remove and discard the supply heater hoses and the water control valve. This is the hose that connects the intake manifold to the heater core. 2. Remove the return heater hose from the heater core at the cowl and install it on the opposite nipple of the heater core. 3. Remove and discard 33 inches off the straight end of the preformed hose, PN 4361146. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 3922 FIGURE 2 4. Clamp water valve, PN 4085474, onto the straight end of heater hose, PN 4361146, which was cut off in Step 3 above. This water valve has an embossed arrow on it to indicate water flow. This arrow must point toward the heater core or precise control of water flow to the heater will be impossible. Proper orientation of this valve is illustrated in Figure 2. Install heater hose, PN 3849197, on the other side of the water valve. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 3923 FIGURE 1 5. Attach supply heater hose bracket, PN 4307576, to the intake manifold boss using enclosed screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 3924 FIGURE 3 6. Install the 90~ bend of the supply heater hose and valve assembly onto the nipple on intake manifold. Route the supply hose past the carburetor choke housing and install the straight end of the hose onto the heater core inlet nipple. Install heater hose onto bracket and clamp securely in place (see Figure 3). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 3925 FIGURE 6 7. Attach Authorization Modification Label, PN 4275086, as illustrated in Figure 6. "M" Body Police With Silicone Heater Hoses 1. Follow the same installation procedure as on "M" body passenger car except silicone heater hose, PN 3849564, must be substituted for passenger car hose, PN 4361146. Silicone heater hose, PN 3849472, must be substituted for passenger car heater hose, PN 3849197. FIGURE 6 2. Attach Authorization Modification Label, PN 4274086, as illustrated in Figure 6. D and W Model Trucks Without Air Conditioning 1. Remove and discard the supply heater hose that connects the intake manifold to the heater core. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 3926 FIGURE 1 2. Attach heater hose bracket to intake manifold boss using screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 3927 FIGURE 5 3. Install 90~ bend of heater supply hose, PN 4361146, onto the intake manifold nipple. Route this hose post carburetor choke housing and install straight end of hose on the heater core nipple. Install hose into bracket and clump hose securely in place (see Figure 5). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 3928 FIGURE 6 4. Attach Authorization Modification Label, PN 4274086, as illustrated in Figure 6. "B" Model Van With and Without Air Conditioning 1. Remove and discard supply heater hose that connects the intake manifold to the heater core or to the water valve, if the vehicle is air conditioning equipped. FIGURE 1 2. Attach heater hose bracket, PN 4307576, to intake manifold boss using screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 3929 3. Install 90~ end of supply heater hose, PN 4361142, onto the intake manifold nipple. Route this heater supply hose post the carburetor choke housing and install the straight end on the heater core or on the water valve, if the vehicle has air conditioning. This hose must be cut to length as required. Install this heater supply hose into the hose bracket previously attached to the intake manifold. FIGURE 4 4. Using tie wraps, PN 6015756, secure supply heater hose to automatic transmission dip stick tube. Use caution as not to deform dip stick tube, as this will make transmission fluid level checks difficult or impossible. Using tie wraps, tie the supply and return heater hoses together as illustrated in Figure 4. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 3930 FIGURE 6 5. Attach Authorization Modification Label, PN 4275086, as illustrated in Figure 6. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 14-30-56-96 Premature Choke Closing "B" Van 0.7 Hrs. D-W Truck and "M" Body Passenger Car 0.5 Hrs. 14-30-56-97 Optional Equipment Air Conditioning "B" Van 0.3 Hrs. D-W Truck and "M" Body Passenger Car 0.4 Hrs. FAILURE CODE: AM - Authorized Modification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 3931 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts Technical Service Bulletin # 181986 Date: 860210 Choke - Hard Hot Restarts Models All 1985-1986 Cars & Trucks Equipped With Quadrajet 4-BBL Carburetors (318-360) Subject Premature Choke Closing Causing Hard Hot Restarts Index DRIVEABILITY Date February 10, 1986 No. 18-19-86 P-362-C Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Partial choke closure which results in a rich condition causing hard worm and hard hot starts in cool or cold ambients. The vehicle may exhibit block smoke out the tailpipe for the first few miles of driving. DIAGNOSIS Remove the air cleaner and visually verify the choke blade is closing when the engine is worm or hot while the ambient is cool or cold. PARTS REQUIRED For 318 4BBL Passenger Cars and 318/360 4BBL D and W Trucks Driveability PN 4397683 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose (Preformed) PN 4361146 1 Heater Hose PN 3849197 1 Screw PN 3730000 "M" body cars will require the following to be ordered separately: 1 Water Valve PN 4085474 3 Tie Wraps PN 6015756 For 318 4BBL Police Vehicles With Silicone Hoses Only Driveability Package PN 4397684 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose (Preformed Silicone) PN 3849564 1 Heater Hose Silicone PN 3849472 1 Water Valve PN 4085474 1 Screw PN 3730000 3 Tie Wraps PN 6015756 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 3937 For 318 4BBL/360 4BBL "B" Model Vans Driveability Package PN 4397685 Contains the following: 1 Heater Hose Bracket PN 4307576 1 Heater Hose PN 4361142 3 Tie Wraps PN 6015756 1 Screw PN 3730000 To be ordered separately for all vehicles: 1 Authorized Modification Label PN 4275086 Repair Procedures This repair procedure involves the routing of the heater supply hose so it contacts the choke housing. The heat from this hose reduces the tendency of the choke to close before the engine cools off. It is, therefore, very important the heater hose be in direct contact with the choke housing. "M" Body Passenger Cars and D-W Series Trucks Without Silicone Heater Hoses and With Air Conditioning 1. Remove and discard the supply heater hoses and the water control valve. This is the hose that connects the intake manifold to the heater core. 2. Remove the return heater hose from the heater core at the cowl and install it on the opposite nipple of the heater core. 3. Remove and discard 33 inches off the straight end of the preformed hose, PN 4361146. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 3938 FIGURE 2 4. Clamp water valve, PN 4085474, onto the straight end of heater hose, PN 4361146, which was cut off in Step 3 above. This water valve has an embossed arrow on it to indicate water flow. This arrow must point toward the heater core or precise control of water flow to the heater will be impossible. Proper orientation of this valve is illustrated in Figure 2. Install heater hose, PN 3849197, on the other side of the water valve. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 3939 FIGURE 1 5. Attach supply heater hose bracket, PN 4307576, to the intake manifold boss using enclosed screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 3940 FIGURE 3 6. Install the 90~ bend of the supply heater hose and valve assembly onto the nipple on intake manifold. Route the supply hose past the carburetor choke housing and install the straight end of the hose onto the heater core inlet nipple. Install heater hose onto bracket and clamp securely in place (see Figure 3). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 3941 FIGURE 6 7. Attach Authorization Modification Label, PN 4275086, as illustrated in Figure 6. "M" Body Police With Silicone Heater Hoses 1. Follow the same installation procedure as on "M" body passenger car except silicone heater hose, PN 3849564, must be substituted for passenger car hose, PN 4361146. Silicone heater hose, PN 3849472, must be substituted for passenger car heater hose, PN 3849197. FIGURE 6 2. Attach Authorization Modification Label, PN 4274086, as illustrated in Figure 6. D and W Model Trucks Without Air Conditioning 1. Remove and discard the supply heater hose that connects the intake manifold to the heater core. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 3942 FIGURE 1 2. Attach heater hose bracket to intake manifold boss using screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 3943 FIGURE 5 3. Install 90~ bend of heater supply hose, PN 4361146, onto the intake manifold nipple. Route this hose post carburetor choke housing and install straight end of hose on the heater core nipple. Install hose into bracket and clump hose securely in place (see Figure 5). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 3944 FIGURE 6 4. Attach Authorization Modification Label, PN 4274086, as illustrated in Figure 6. "B" Model Van With and Without Air Conditioning 1. Remove and discard supply heater hose that connects the intake manifold to the heater core or to the water valve, if the vehicle is air conditioning equipped. FIGURE 1 2. Attach heater hose bracket, PN 4307576, to intake manifold boss using screw, PN 3730000, as illustrated in Figure 1. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 3945 3. Install 90~ end of supply heater hose, PN 4361142, onto the intake manifold nipple. Route this heater supply hose post the carburetor choke housing and install the straight end on the heater core or on the water valve, if the vehicle has air conditioning. This hose must be cut to length as required. Install this heater supply hose into the hose bracket previously attached to the intake manifold. FIGURE 4 4. Using tie wraps, PN 6015756, secure supply heater hose to automatic transmission dip stick tube. Use caution as not to deform dip stick tube, as this will make transmission fluid level checks difficult or impossible. Using tie wraps, tie the supply and return heater hoses together as illustrated in Figure 4. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 3946 FIGURE 6 5. Attach Authorization Modification Label, PN 4275086, as illustrated in Figure 6. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 14-30-56-96 Premature Choke Closing "B" Van 0.7 Hrs. D-W Truck and "M" Body Passenger Car 0.5 Hrs. 14-30-56-97 Optional Equipment Air Conditioning "B" Van 0.3 Hrs. D-W Truck and "M" Body Passenger Car 0.4 Hrs. FAILURE CODE: AM - Authorized Modification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 181986 > Feb > 86 > Choke - Hard Hot Restarts > Page 3947 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications REFRIGERANT CAPACITIES DODGE/PLYMOUTH TRUCKS 1992 Ram 50 pickup ............................................................................................................................ .............................................. 0.8 kg (30 oz.) Ramcharger .................................................................. ............................................................................................................. 1.3 kg (44 oz.) 1992-91 Dakota ................................................................................................................................... ................................................... 1.2 kg (40 oz.) B-Series van ............................................................ .................................................................................................................. 1.3 kg (44 oz.) with rear unit ....................................................................................................................................................... ...................... 1.8 kg (62 oz.) 1992-90 Caravan, Mini Ram, Voyager ................................................................................................................................................... 0.9 kg (32 oz.) with rear unit ........................................................................................................................... .................................................. 1.2 kg (43 oz.) 1992-88 D/W-Series pickup ................................................................................................................. .................................................. 1.3 kg (44 oz.) 1990-87 Dakota ................................................................................................................................... ................................................... 1.3 kg (44 oz.) 1990-83 B-Series van .......................................................................................................................... .................................................... 1.4 kg (48 oz.) with rear unit ........................................................... .................................................................................................................. 1.8 kg (62 oz.) 1989-84 Caravan, Mini-Ram, Voyager ................................................................................................................................................... 1.1 kg (38 oz.) with rear AC ............................................................................................................................ ................................................. 1.3 kg (44 oz.) 1987-83 D/W-Series pickup ................................................................................................................. .................................................. 1.1 kg (40 oz.) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 3952 Refrigerant: Fluid Type Specifications A/C Refrigerant Specifications A/C Refrigerant Specifications Refrigerant Types R-12 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications Refrigerant Oil: Specifications Capacities Capacities Capasity Viscosity 7-7.25 oz (US) 500 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Rear Shoulder Belt - Retrofit Kits Seat Belt: Technical Service Bulletins Rear Shoulder Belt - Retrofit Kits Models 1979-90 B & AB Bodies D & AD Bodies Subject Rear Shoulder Belt Retrofit Kits Index BODY AND SHEET METAL Date June 4, 1990 No. 23-09-90 P-1650 (C23-04-0) BODY CODE LEGEND B & AB RAM WAGON D & AD RAM PICKUP/RAM CAB & CHASSIS/RAMCHARGER (RWD, 4WD) POWER RAM CAB & CHASSIS (4WD) PROCEDURE In response to customer interest, rear seat shoulder belt kits have been developed and are now available for 1979-90 Ram Wagon (5 & 8 passenger B-Vans only) and 1981-90 Ramcharger Models. The kits listed below can be installed per the instructions in the kit. The customer is responsible for all expenses for parts and labor. Body Model Type Qty Part No. B & AB 1979-90 Ram Wagon 1 82400478 (First bench) B & AB 1979-90 Ram Wagon 1 82400479 (Second bench) D & AD 1981-90 Ramcharger 1 82400480 NOTE: EACH KIT CONTAINS THE PARTS, TEMPLATES AND INSTRUCTION SHEETS NECESSARY FOR ONE SEAT. POLICY: For information only. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Technical Service Bulletins > Seat Belt Extender - Information Seat Belt Extension: Technical Service Bulletins Seat Belt Extender - Information Models All Domestic Vehicles Built After 1985 Subject Seat Belt Extender Index BODY Date December 29, 1986 No. 23-17-86 P-4537 This bulletin supersedes Technical Service Bulletin 23-08-85, which should be removed from your files. Due to the increased emphasis on seat belt use, customers may inquire as to the availability of seal belt extenders. PARTS REQUIRED Front Or Rear Seat Belt Extender (Available in Black Only) Vehicles equipped with seat belt buckles using a red end release push button. ^ 1987 Shadow/Sundance (P Body) PN 4402887 ^ 1987 LeBaron Coupe & Convertible (J Body) PN 4402887 ^ 1987 Dakota Pick Up Truck (N Body) PN 4402887 ^ All Future Vehicles Built With Seat Belt Buckles Using a Red End Release Push Button PN 4402887 All vehicles equipped with seat belt buckles using a silver and black center release push button PN 4364849 IT IS VERY IMPORTANT THAT THE CUSTOMERS BE INSTRUCTED IN THE PROPER USE OF THE BELT EXTENDER AND ALSO ADHERE TO THE FOLLOWING WARNING AS DESCRIBED IN THE INSTRUCTION SHEET WHICH IS INCLUDED IN THE BELT PACKAGE. WARNING: THE SEAT BELT EXTENDER IS INTENDED FOR USE ONLY WHEN THE SEAT BELT IS NOT LONG ENOUGH TO FIT AROUND AN OCCUPANT OR CHILD RESTRAINT SEAT. IT SHOULD BE REMOVED AND STOWED WHEN NOT IN USE. INCORRECT USE OF SEAT BELT EXTENDER MAY RESULT IN SERIOUS INJURY. FITS ONLY 1975 AND LATER MODEL CARS AND TRUCKS MANUFACTURED BY CHRYSLER CORPORATION. DO NOT USE ON ANY OTHER VEHICLES. POLICY: ^ Upon customer request dealer should order seat belt extender. ^ Extender will be provided to the dealer on a "gratis basis." ^ Extender should be provided to customer at "no charge". Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions Accessory Delay Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3971 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3972 Accessory Delay Module: Electrical Diagrams Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3973 Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Customer Interest: > 080985 > Apr > 85 > Radio - Rapid Crackling Noise in FM Mode Radio/Stereo: Customer Interest Radio - Rapid Crackling Noise in FM Mode Models All 1985 Carbureted Vehicles (Except 2.6L Engine) Equipped . With AM/FM Stereo Radio (Sales Code RAL, RAN, or RAY) Subject FM Radio Noise Induced by Electronic Voltage Regulator Index ELECTRICAL Date April 1, 1985 No.. 08-09-85 SYMPTOM/CONDITION Vehicle may exhibit radio interference in the FM mode, best described as a "rapid cracking noise." Intensity may be high or low. It is not a whine or static noise. DIAGNOSIS This condition only applies to subject vehicles built on or before December 21, 1984 MDH 12-12-XX. Check with hood closed and engine running slightly above idle in park or neutral. Tune to weak FM station (prefer using station customer listens to). Switch off all other electrical loads. If noise is heard, have someone disconnect electronic voltage regulator and close the hood. If noise is eliminated, replace electronic voltage regulator with PN 4379100. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 08-20-10-01 FWD . . . . . . . . . 0.2 Hrs. 08-20-10-05 RWD . . . . . . . . . 0.2 Hrs. FAILURE CODE: 58 - Internal Defect Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo: > 080985 > Apr > 85 > Radio - Rapid Crackling Noise in FM Mode Radio/Stereo: All Technical Service Bulletins Radio - Rapid Crackling Noise in FM Mode Models All 1985 Carbureted Vehicles (Except 2.6L Engine) Equipped . With AM/FM Stereo Radio (Sales Code RAL, RAN, or RAY) Subject FM Radio Noise Induced by Electronic Voltage Regulator Index ELECTRICAL Date April 1, 1985 No.. 08-09-85 SYMPTOM/CONDITION Vehicle may exhibit radio interference in the FM mode, best described as a "rapid cracking noise." Intensity may be high or low. It is not a whine or static noise. DIAGNOSIS This condition only applies to subject vehicles built on or before December 21, 1984 MDH 12-12-XX. Check with hood closed and engine running slightly above idle in park or neutral. Tune to weak FM station (prefer using station customer listens to). Switch off all other electrical loads. If noise is heard, have someone disconnect electronic voltage regulator and close the hood. If noise is eliminated, replace electronic voltage regulator with PN 4379100. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 08-20-10-01 FWD . . . . . . . . . 0.2 Hrs. 08-20-10-05 RWD . . . . . . . . . 0.2 Hrs. FAILURE CODE: 58 - Internal Defect Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo: > 080385 > Feb > 85 > Radio/Clock - Defeat Function Explanation Radio/Stereo: All Technical Service Bulletins Radio/Clock - Defeat Function Explanation Models All 1985 Equipped With Radio Subject Clock Defeat Function Index ELECTRICAL Date February 18, 1985 No.. 08-03-85 P-540-C 1985 vehicles are equipped with radios that have a clock defeat function. The defeat mode is provided to eliminate the clock display whenever the vehicle has other options that contain a clock. Defeat functions operate in the following manner: NOTE: WHENEVER THE BATTERY IS DISCONNECTED FOR ANY REASON, TURN OFF RADIO BEFORE RECONNECTING THE BATTERY. THIS PROCEDURE SHOULD ALSO BE PERFORMED PRIOR TO REMOVING RADIO FOR REPAIR OF AN INOPERATIVE CLOCK. AM FM STEREO Defeat: With the radio ON and time displayed, press the SET button once, then press the volume control knob once and finally, press the AM FM button three times. To restore: Repeat the above procedure. AM STEREO & FM STEREO WITH CASSETTE Defeat: With the radio ON and time displayed, using two fingers, press any one of the six memory buttons and the volume control knob at the same time. Then press the AM FM button three times. To restore: Repeat the above procedure. ULTIMATE SOUND SYSTEM - AM STEREO & FM STEREO WITH CASSETTE To defeat time display: With the radio ON and time displayed, press the SET button once, then press the volume control knob once and finally press the 70 us button twice. To restore the display repeat the above procedure. NOTE: TIME CANNOT BE SET, DEFEATED OR RESTORED WHILE THE TAPE IS PLAYING. Information only. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radio/Stereo: > 080385 > Feb > 85 > Radio/Clock - Defeat Function Explanation Radio/Stereo: All Technical Service Bulletins Radio/Clock - Defeat Function Explanation Models All 1985 Equipped With Radio Subject Clock Defeat Function Index ELECTRICAL Date February 18, 1985 No.. 08-03-85 P-540-C 1985 vehicles are equipped with radios that have a clock defeat function. The defeat mode is provided to eliminate the clock display whenever the vehicle has other options that contain a clock. Defeat functions operate in the following manner: NOTE: WHENEVER THE BATTERY IS DISCONNECTED FOR ANY REASON, TURN OFF RADIO BEFORE RECONNECTING THE BATTERY. THIS PROCEDURE SHOULD ALSO BE PERFORMED PRIOR TO REMOVING RADIO FOR REPAIR OF AN INOPERATIVE CLOCK. AM FM STEREO Defeat: With the radio ON and time displayed, press the SET button once, then press the volume control knob once and finally, press the AM FM button three times. To restore: Repeat the above procedure. AM STEREO & FM STEREO WITH CASSETTE Defeat: With the radio ON and time displayed, using two fingers, press any one of the six memory buttons and the volume control knob at the same time. Then press the AM FM button three times. To restore: Repeat the above procedure. ULTIMATE SOUND SYSTEM - AM STEREO & FM STEREO WITH CASSETTE To defeat time display: With the radio ON and time displayed, press the SET button once, then press the volume control knob once and finally press the 70 us button twice. To restore the display repeat the above procedure. NOTE: TIME CANNOT BE SET, DEFEATED OR RESTORED WHILE THE TAPE IS PLAYING. Information only. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions Radio/Stereo: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 3999 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4000 Radio/Stereo: Electrical Diagrams Fig. 29 Radio Wiring Circuit (AM). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4001 Fig. 30 Radio Wiring Circuit (Stereo W/Dual Speakers). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4002 Fig. 31 Radio Wiring Circuit (Stereo W/Four Speakers, Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 4003 Fig. 31 Radio Wiring Circuit (Stereo W/Four Speakers, Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Page 4004 Radio/Stereo: Service and Repair 1980-81 TRAIL DUSTER & 1980-87 RAMCHARGER & CONVENTIONAL CABS 1. Disconnect battery ground cable. 2. Remove instrument cluster bezel attaching screws, then the bezel. 3. Remove left air conditioner duct if equipped. 4. Disconnect antenna lead, speaker leads and electrical connectors, then remove radio to mounting bracket attaching nut. 5. Remove radio to cluster attaching bolts, then remove radio through cluster housing opening. 6. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions Accessory Delay Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4010 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4011 Accessory Delay Module: Electrical Diagrams Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4012 Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Trailer Tow Wiring/Components - Installation Cautions Trailer Adapter Kit: Technical Service Bulletins Trailer Tow Wiring/Components - Installation Cautions NO.: 08-05-91 GROUP: ELECTRICAL DATE: Apr. 22, 1991 SUBJECT: Trailer Tow Wiring Installation MODELS: ALL DODGE TRUCKS DISCUSSION: Improper installation of trailer tow wiring or electrical components can cause erratic operation of the vehicles electrical system. When installing wiring or additional components, or diagnosing a vehicle with erratic electrical operation, observe the following guidelines. ^ Inspect trailer wiring for bare or broken wires, corroded splices and terminals, shorted lamp sockets, poor or insufficient grounding between the trailer wiring system and trailer frame. ^ When connecting lighting circuits, use a factory trailer tow wiring harness or a Mopar service kit if available. Mopar kits include mating connectors and do not require cutting or splicing of vehicle wiring. If cutting or splicing is required, the attached Wiring Procedure should be followed. ^ When installing any electrical equipment (such as electric brakes, battery chargers, lighting, and winches) make sure that the tow vehicles electrical ground is hard wired to the trailer electrical ground. Ground wires should be attached to a clean, bare metal surface, not to a painted surface. DO NOT rely on the trailer hitch coupling for ground. ^ When using butt splice connectors, test the splice integrity by pulling on the wires after crimping. ^ DO NOT use insulation displacement or insulation piercing crimp type terminals. ^ Some electrical equipment will require splicing into the vehicle wiring. Follow the attached Wiring Procedure when installing these components. WIRING PROCEDURE 1. With the ignition key in the OFF position, disconnect the battery. 2. Remove one inch of insulation from each wire to be connected. 3. Slide a piece of heat shrink tubing (PN 4419644) onto one wire. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Trailer Tow Wiring/Components - Installation Cautions > Page 4018 4. Spread the strands of each wire apart (Example 1). 5. Push the ends of the wire together until the strands are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the twisted wire ends using a ROSIN CORE SOLDER. 8. Slide the piece of heat shrink tubing down to cover the splice. Be careful to center the tubing on the splice. Using a heat gun, heat the tubing until it shrinks and seals the splice. 9. Connect the battery. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4025 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest: > 236394 > Aug > 94 > Cowl - Creaking/Popping Sounds Cowl: Customer Interest Cowl - Creaking/Popping Sounds NO: 23-63-94 GROUP: Body EFFECTIVE DATE: Aug. 26, 1994 SUBJECT: Cowl Cracks MODELS: 1993 and Prior (AD) Ram Truck/Ramcharger SYMPTOM/CONDITION: Cracking or popping sounds coming from the cowl area at the lower corners of the windshield. DIAGNOSIS: Inspect the area underneath the fender at the cowl welds. The fenders must be removed to see the cracks. If cracks are present, perform the repair procedure (See Illustration). PARTS REQUIRED: AR 4797018 Cowl Reinforcement-Left AR 4797019 Cowl Reinforcement-Right 3 4746924 3/16" Structural Rivet 1 3M P/N - 08456 3M Panel Adhesive Compound 30 1 3M P/N - 08198 Applicator Gun 1 3M P/N - 08193 Applicator Nozzle REPAIR PROCEDURE: This bulletin involves repairing the cracks and installing a reinforcement. 1. Remove the wiper arms. 2. Remove the cowl screen. 3. Remove the hood with the hood hinges attached. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest: > 236394 > Aug > 94 > Cowl - Creaking/Popping Sounds > Page 4034 4. Remove the front fender or fenders. 5. Drill stop the crack ends with a 1/16" drill. 6. Grind any rough edges from the area where the reinforcement will be secured. Grind the surface of the area to provide a good surface for the adhesive to adhere. 7. Grind the inside surface of the patch. 8. Grind away any paint from the vertical seam to prepare for application of adhesive (See Illustration) and clean the area with a solvent such as Mopar Super Kleen, P/N 4318015. 9. Clean the cowl and the reinforcement with a solvent such as Mopar Super Kleen, P/N 4318015. 10. Assemble the adhesive cartridge to the applicator gun following the manufacturers instructions. 11. Apply adhesive to the cowl approximately 1/16" thick and apply a bead to the vertical seam as shown. 12. Position the patch on the cowl. 13. Drill the 3/16" holes in the cowl and install the rivets, one at a time, until the patch is secure. Clean any excess adhesive from around the reinforcement. 14. Allow 4 hours for the epoxy to cure. 15. Prime the area and apply a coating of rustproofing to minimize corrosion. 16. Seal the panel joint seam at the windshield gasket with RTV to prevent leaks (See Illustration). 17. Install the fender and hood. 18. Install the cowl screen and wiper arms. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 23-00-27-90 (One Side) 3.6 Hrs. 23-00-27-91 (Both Sides 6.0 Hrs. FAILURE CODE: XX - Service Adjustment Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 236394 > Aug > 94 > Cowl - Creaking/Popping Sounds Cowl: All Technical Service Bulletins Cowl - Creaking/Popping Sounds NO: 23-63-94 GROUP: Body EFFECTIVE DATE: Aug. 26, 1994 SUBJECT: Cowl Cracks MODELS: 1993 and Prior (AD) Ram Truck/Ramcharger SYMPTOM/CONDITION: Cracking or popping sounds coming from the cowl area at the lower corners of the windshield. DIAGNOSIS: Inspect the area underneath the fender at the cowl welds. The fenders must be removed to see the cracks. If cracks are present, perform the repair procedure (See Illustration). PARTS REQUIRED: AR 4797018 Cowl Reinforcement-Left AR 4797019 Cowl Reinforcement-Right 3 4746924 3/16" Structural Rivet 1 3M P/N - 08456 3M Panel Adhesive Compound 30 1 3M P/N - 08198 Applicator Gun 1 3M P/N - 08193 Applicator Nozzle REPAIR PROCEDURE: This bulletin involves repairing the cracks and installing a reinforcement. 1. Remove the wiper arms. 2. Remove the cowl screen. 3. Remove the hood with the hood hinges attached. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 236394 > Aug > 94 > Cowl - Creaking/Popping Sounds > Page 4040 4. Remove the front fender or fenders. 5. Drill stop the crack ends with a 1/16" drill. 6. Grind any rough edges from the area where the reinforcement will be secured. Grind the surface of the area to provide a good surface for the adhesive to adhere. 7. Grind the inside surface of the patch. 8. Grind away any paint from the vertical seam to prepare for application of adhesive (See Illustration) and clean the area with a solvent such as Mopar Super Kleen, P/N 4318015. 9. Clean the cowl and the reinforcement with a solvent such as Mopar Super Kleen, P/N 4318015. 10. Assemble the adhesive cartridge to the applicator gun following the manufacturers instructions. 11. Apply adhesive to the cowl approximately 1/16" thick and apply a bead to the vertical seam as shown. 12. Position the patch on the cowl. 13. Drill the 3/16" holes in the cowl and install the rivets, one at a time, until the patch is secure. Clean any excess adhesive from around the reinforcement. 14. Allow 4 hours for the epoxy to cure. 15. Prime the area and apply a coating of rustproofing to minimize corrosion. 16. Seal the panel joint seam at the windshield gasket with RTV to prevent leaks (See Illustration). 17. Install the fender and hood. 18. Install the cowl screen and wiper arms. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 23-00-27-90 (One Side) 3.6 Hrs. 23-00-27-91 (Both Sides 6.0 Hrs. FAILURE CODE: XX - Service Adjustment Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cowl: > 231585 > Oct > 85 > Bench Seat Cushion - Not Firm or Collapses Seat Cushion: All Technical Service Bulletins Bench Seat Cushion - Not Firm or Collapses Models 1985 Conventional Cab Truck With Bench Seat Subject Lack of Firmness or Cushion Collapse Index BODY Date October 7, 1985 No. 23-15-85 SYMPTOM/CONDITION Customer complaints of lack of firmness, pad deterioration or cushion collapse, after a very short time or very low mileage on subject model vehicles, built between October, 1984 and the end of February, 1985, can be resolved by replacing the seat cushion pad. PARTS REQUIRED 1 - Seat Cushion Pad PN 4211581 REPAIR PROCEDURE 1. Shift seat to most forward position. 2. Remove seat back pivot arm side covers and pivot bolts. 3. Lifting seat back lock latch, remove seat back assembly from vehicle. 4. From under vehicle, remove four seat track mounting nuts and remove seat cushion assembly from vehicle. 5. Remove all trim cover retaining hog rings from underside of cushion assembly and remove trim cover and cushion pad from cushion frame. NOTE: IT MAY BE NECESSARY TO LOOSEN THE SEAT BACK STOP BRACKETS ON EACH SIDE OF CUSHION FRAME. 6. Position new cushion on bench with bottom side up, position cushion frame and backing board over cushion pad. Hog ring rear cushion pad attachment wire to cushion frame grid bars. 7. Turn cushion pad and frame assembly upright. Carefully position trim cover over cushion pad and frame assembly. 8. Roll cushion pad, frame and trim cover upside down and hog ring trim cover to grid bars on underside of cushion assembly. NOTE: INSTALL HOG RINGS FROM CENTER OF CUSHION OUT TO ENDS AT REAR OF TRIM COVER FIRST, THEN AT FRONT OF COVER IN THE SAME MANNER AND THEN THE ENDS. (THIS WILL HELP TO MINIMIZE WRINKLING OF THE COVER). 9. Tighten seat back stop brackets. 10. Position seat in vehicle and install and tighten the four mounting nuts. 11. Position seat back to frame and install and tighten pivot bolts. Install seat pivot arm side covers. 12. Verify seat operation. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Refer to Labor Operation Time Schedule for operation and time. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cowl: > 231585 > Oct > 85 > Bench Seat Cushion - Not Firm or Collapses > Page 4046 FAILURE CODE: 20 - Collapsed Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cowl: > 231585 > Oct > 85 > Bench Seat Cushion - Not Firm or Collapses > Page 4052 FAILURE CODE: 20 - Collapsed Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair Power Window Regulator Mounting Removal Remove the trim panel(s) to gain access to the window motor. Disconnect the wire connector from the motor. Remove the rivets that secure the regulator to the inner door panel. Remove the screw that holds the window motor tie down bracket to the inner door panel (if equipped). Manually move the regulator assembly to disengage the regulator slider from the glass lift channel. Secure the window glass in the up position with several straps of duct tape looped over the window frame. Remove the regulator through the door access hole. If window motor needs to be removed from the regulator, secure the regulator in a vise to prevent the sector gear from moving.[1] Remove three motor attaching screws and remove window motor from the regulator. [1] WARNING:If the sector gear is not properly secured to prevent movement, the counter balance spring will cause the regulator arm to move rapidly when the window motor is removed from the regulator. This may cause personal injury. Installation Install window motor to regulator using original mounting screws. Inspect the sector gear teeth and window motor teeth for proper mesh. Remove the regulator assembly from the vise and insert through the door access panel. Manually position the regulator arm slide in the window lift channel. Secure the regulator assembly to the inner door panel using either new rivets or matching nut, bolt, and washer sets. Install screw to motor tie down bracket (if equipped). Connect motor wiring to harness and test system for proper operation. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Component Information > Diagrams > Diagram Information and Instructions Trunk / Liftgate: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Component Information > Diagrams > Diagram Information and Instructions > Page 4063 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Component Information > Diagrams > Diagram Information and Instructions > Page 4064 Fig. 27 Liftgate Ajar & Rear Courtesy Lamps Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Trailer Tow Wiring/Components - Installation Cautions Trailer Adapter Kit: Technical Service Bulletins Trailer Tow Wiring/Components - Installation Cautions NO.: 08-05-91 GROUP: ELECTRICAL DATE: Apr. 22, 1991 SUBJECT: Trailer Tow Wiring Installation MODELS: ALL DODGE TRUCKS DISCUSSION: Improper installation of trailer tow wiring or electrical components can cause erratic operation of the vehicles electrical system. When installing wiring or additional components, or diagnosing a vehicle with erratic electrical operation, observe the following guidelines. ^ Inspect trailer wiring for bare or broken wires, corroded splices and terminals, shorted lamp sockets, poor or insufficient grounding between the trailer wiring system and trailer frame. ^ When connecting lighting circuits, use a factory trailer tow wiring harness or a Mopar service kit if available. Mopar kits include mating connectors and do not require cutting or splicing of vehicle wiring. If cutting or splicing is required, the attached Wiring Procedure should be followed. ^ When installing any electrical equipment (such as electric brakes, battery chargers, lighting, and winches) make sure that the tow vehicles electrical ground is hard wired to the trailer electrical ground. Ground wires should be attached to a clean, bare metal surface, not to a painted surface. DO NOT rely on the trailer hitch coupling for ground. ^ When using butt splice connectors, test the splice integrity by pulling on the wires after crimping. ^ DO NOT use insulation displacement or insulation piercing crimp type terminals. ^ Some electrical equipment will require splicing into the vehicle wiring. Follow the attached Wiring Procedure when installing these components. WIRING PROCEDURE 1. With the ignition key in the OFF position, disconnect the battery. 2. Remove one inch of insulation from each wire to be connected. 3. Slide a piece of heat shrink tubing (PN 4419644) onto one wire. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Trailer Tow Wiring/Components - Installation Cautions > Page 4070 4. Spread the strands of each wire apart (Example 1). 5. Push the ends of the wire together until the strands are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the twisted wire ends using a ROSIN CORE SOLDER. 8. Slide the piece of heat shrink tubing down to cover the splice. Be careful to center the tubing on the splice. Using a heat gun, heat the tubing until it shrinks and seals the splice. 9. Connect the battery. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Locks > Door Lock <--> [Door Locks] > Component Information > Specifications Door Lock: Specifications Power Door Lock Circuit Breaker Specification ................................................................................................................................................. 30 amps Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Locks > Door Lock <--> [Door Locks] > Component Information > Diagrams > Diagram Information and Instructions Door Lock: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Locks > Door Lock <--> [Door Locks] > Component Information > Diagrams > Diagram Information and Instructions > Page 4077 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Locks > Door Lock <--> [Door Locks] > Component Information > Diagrams > Diagram Information and Instructions > Page 4078 Door Lock: Electrical Diagrams Fig. 28 Power Door Locks & Power Windows Wiring Circuit (Part 1 of 2). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Locks > Door Lock <--> [Door Locks] > Component Information > Diagrams > Diagram Information and Instructions > Page 4079 Fig. 28 Power Door Locks & Power Windows Wiring Circuit (Part 2 of 2). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Locks > Door Lock <--> [Door Locks] > Component Information > Diagrams > Diagram Information and Instructions > Page 4080 Fig. 28 Power Door Locks & Power Windows Wiring Circuit (Part 1 of 2). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Locks > Door Lock <--> [Door Locks] > Component Information > Diagrams > Diagram Information and Instructions > Page 4081 Fig. 28 Power Door Locks & Power Windows Wiring Circuit (Part 2 of 2). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Motor <--> [Power Door Lock Actuator] > Component Information > Locations Power Door Lock Motor: Locations Power Door Lock Equipment The door solenoid is located inside each of the doors. Its bracket is bolted to the inner door panel with slots provided for adjustment purposes. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Motor <--> [Power Door Lock Actuator] > Component Information > Locations > Page 4086 Power Door Lock Motor: Testing and Inspection To determine which door solenoid is defective, check for proper lock/unlock operation at each door. If none of the solenoids operate, the problem may be due to a shorted door solenoid. Disconnecting the defective solenoid will allow the other(s) to operate. To test an individual door solenoid, remove the door trim panel(s) to gain access to the door solenoid. Unplug the door solenoid connector and connect a voltmeter between the "lock" wire (OR) and a known good ground. Move the lock knob to the lock position and check for available voltage. Connect the voltmeter to the "unlock" (LB) wire and move the lock knob to the unlock position again checking the available voltage. If voltage is present in both lock knob positions, the door solenoid is defective. If voltage is not present in one position or neither positions, the relay, door switch, or connecting wires may be defective. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Motor <--> [Power Door Lock Actuator] > Component Information > Locations > Page 4087 Power Door Lock Motor: Adjustments Remove the door trim panel(s) to gain access to the door solenoid. Door Lock Solenoid Loosen the solenoid attaching screws. Press down on the lock knob while pushing up on the solenoid until the solenoid plunger bottoms out in the solenoid housing. Tighten the solenoid attaching screws. Test the solenoid for proper operation before assembling the door trim panel(s). Check all other solenoids for proper operation and repair as necessary. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Motor <--> [Power Door Lock Actuator] > Component Information > Locations > Page 4088 Power Door Lock Motor: Service and Repair Remove door trim panel(s). Power Door Lock Equipment Unplug wire connector from door solenoid. Remove retaining clip from door solenoid link. Remove door solenoid mounting bolts. Install new solenoid loosely with original mounting bolts. Install link and retaining clip to door solenoid. Adjust door solenoid. Attach wire plug to door solenoid and test power door lock system for proper operation. Install door trim panel(s). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Door Lock Relay Location Power Door Lock Relay: Locations Door Lock Relay Location Door Lock And Power Window Circuit Breaker And Relays Location The relay is located behind the dash panel, to the left of the glove box. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Door Lock Relay Location > Page 4093 Power Door Lock Relay: Locations Electric Door Lock Relays Electric Door Lock Relay Location. Behind LH Side Of I/P Applicable to: 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Page 4094 Power Door Lock Relay: Testing and Inspection To test the relay, move either of the front lock knobs to the lock and unlock positions. An audible clicking sound should be heard from under the dash near the steering column support. If the sound is heard while operating one knob but not the other, a defective switch or wiring may be at fault. If a clicking sound is not heard, locate the relay and test as follows: 1. Check for power by back probing the LG wire at the relay. ^ If power is present, go to step 2. ^ If power is not present, check the circuit breaker and the wire between the relay and the circuit breaker. 2. Back probe the OR wire at the relay and move the lock knob to the lock position. Battery voltage should be momentarily present, indicating that the relay operates in the lock position. ^ If power is present go to step 4. ^ If power is not present, go to step 3. 3. Backprobe the VT wire and move the lock knob to the lock position. ^ If power is present, the relay is defective. ^ If power is not present, the door switch or wiring may be defective. 4. Backprobe the LB wire at the relay and move the lock knob to the unlock position. Battery voltage should be momentarily present, indicating that the relay operates in the unlock position. ^ If power is present, the relay is operating properly. ^ If power is not present, go to step 5. 5. Backprobe the LG wire and move the lock knob to the unlock position. ^ If power is present, the relay is defective. ^ If power is not present, the door switch or wiring may be defective. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations > Page 4095 Power Door Lock Relay: Service and Repair Door Lock And Power Window Circuit Breaker And Relays Location Disconnect the battery negative terminal. Remove the wire connector from the relay. Remove the attaching bolt that holds the relay to the instrument panel. Install by attaching relay to the instrument panel and connecting the wires to the relay. Connect the battery negative terminal and test the system for proper operation. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Door Lock Switch <--> [Power Door Lock Switch] > Component Information > Locations Door Lock Switch: Locations Power Door Lock Equipment The door switch is located inside each of the front doors, just above the access opening. It is riveted to the inner door panel and has connecting rods to the lock knob and the door latch. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Door Lock Switch <--> [Power Door Lock Switch] > Component Information > Locations > Page 4099 Door Lock Switch: Testing and Inspection NOTE: The door switches are available only on the front doors. Remove the door trim to gain access to the door switch. Power Door Lock Equipment Unplug the door switch connector and connect an ohmmeter between the center terminal and one of the outer terminals of the door switch. Move the lock knob between the lock and unlock positions several times. The ohmmeter should show continuity (zero resistance) in only one of the positions. Connect the ohmmeter between the center terminal and the other outer terminal and repeat the lock knob movement. The ohmmeter should now show continuity Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Door Lock Switch <--> [Power Door Lock Switch] > Component Information > Locations > Page 4100 (zero resistance) in the other lock knob position. If the door switch does not test properly, it is defective. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Door Lock Switch <--> [Power Door Lock Switch] > Component Information > Locations > Page 4101 Door Lock Switch: Service and Repair Remove the battery negative cable. Remove door trim and panel(s) Power Door Lock Equipment Disconnect wire plug from door switch. Disconnect lock knob rod retaining clip and remove lock knob rod from door switch. Disconnect retaining clip on link between latch assembly and door switch. Center punch door switch mounting rivet and drill out rivet head. Install new door switch using either a new rivet or a matching nut, bolt, and washer assembly. Install link between latch assembly and door switch. Install lock knob rod to door switch. Connect wire plug to door switch. Install battery negative cable and test power door lock system. Install door trim panel(s). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 231187 > Aug > 87 > Piant - Small Cracks Visible Paint: Customer Interest Piant - Small Cracks Visible Models 1985-1987 "L", "P", "H", "K"', "G", "D", "W" & "N" Body Subject "Crows Foot" Shaped Paint Cracking Index BODY Date August 31, 1987 No. 23-11-87 (C9-23) P-3095 FIGURE 1 SYMPTOM/CONDITION Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 231187 > Aug > 87 > Piant - Small Cracks Visible > Page 4111 Vehicles with darker colors may exhibit small cracks in the paint surface. The cracks start from a center point and branch out, normally with three to five lines resembling a "crows foot" (Figure 1). Surrounding the "crows foot" shaped cracks may be short straight or "V" shaped cracks (Figure 1). Of the body types listed above, the following bodies are not affected by this condition. Assembly Plant Model Year/ Vehicle Code (Character Body Assembly Plant 11 of VIN) 1985-87 "K" 4 Door Jefferson C 1987 "G" St. Louis I G NOTE: BECAUSE THE AFFECTED VEHICLES WERE ORIGINALLY MANUFACTURED WITH PPG MATERIAL, THE MATERIALS REFERENCED BELOW ARE PPG (FORMERLY DITZLER). EQUIVALENT MATERIALS ARE AVAILABLE THROUGH OTHER MANUFACTURERS AND CAN BE USED, AS LONG AS THE COMPLETE SYSTEM AND MANUFACTURER'S PROCEDURES ARE FOLLOWED. Please furnish your body shop foreman and/or painter with this information. REPAIR PROCEDURE 1. The panel that contains the paint cracks must be sanded to the primer surface. NOTE: IN MOST CASES, THE CRACKS ARE LIMITED TO THE TOP CLEAR COAT AND BASE COLOR COAT. CARE SHOULD BE TAKEN NOT TO SAND OR STRIP PAST THE PRIMER SURFACE UNLESS THE CRACKS GO THROUGH THE PRIMER. DOING SO WILL REMOVE THE ORIGINAL COATING APPLIED FOR RUST PROTECTION. 2. Any areas sanded or chemically stripped to metal must be treated with Galvo Prep - DX 520, or equivalent, and primed with DP 40 Epoxy Chromate Primer, or equivalent. 3. The entire panel must then be primed with a two-component primer surfacer (K 200 - part "A" and K 201 - part B, or equivalent). 4. The entire surface must then be scuff sanded. 5. The panel should then be top coated with the appropriate DBU base color coat and DAU 82 or DBU 88 clear coat, or equivalent. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Use of the following Labor Operation will require Zone authorization. 23-77-93-00 . . . . . . . . Actual Time (A/T) FAILURE CODE: P3 - Checking or Cracking Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 230291 > Feb > 91 > Paint - Variance Program Paint: All Technical Service Bulletins Paint - Variance Program SUBJECT: Color Variance Program NO.: 23-02-91 GROUP: BODY DATE: Feb. 11, 1991 MODELS: 1984 - 1991 All Domestic Models DISCUSSION: The color variance charts from BASF, Sherwin-Williams, Martin Senour, Acme and Rogers are being sent for use in solving off-color paint problems. The variance charts provide an alternate color that will help the painter achieve a good match or a closer match than the factory pack. Other manufacturers have paint variance programs available that are in a format not suitable for mailing with a bulletin. Check with your local jobber. POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 231187 > Aug > 87 > Piant - Small Cracks Visible Paint: All Technical Service Bulletins Piant - Small Cracks Visible Models 1985-1987 "L", "P", "H", "K"', "G", "D", "W" & "N" Body Subject "Crows Foot" Shaped Paint Cracking Index BODY Date August 31, 1987 No. 23-11-87 (C9-23) P-3095 FIGURE 1 SYMPTOM/CONDITION Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 231187 > Aug > 87 > Piant - Small Cracks Visible > Page 4121 Vehicles with darker colors may exhibit small cracks in the paint surface. The cracks start from a center point and branch out, normally with three to five lines resembling a "crows foot" (Figure 1). Surrounding the "crows foot" shaped cracks may be short straight or "V" shaped cracks (Figure 1). Of the body types listed above, the following bodies are not affected by this condition. Assembly Plant Model Year/ Vehicle Code (Character Body Assembly Plant 11 of VIN) 1985-87 "K" 4 Door Jefferson C 1987 "G" St. Louis I G NOTE: BECAUSE THE AFFECTED VEHICLES WERE ORIGINALLY MANUFACTURED WITH PPG MATERIAL, THE MATERIALS REFERENCED BELOW ARE PPG (FORMERLY DITZLER). EQUIVALENT MATERIALS ARE AVAILABLE THROUGH OTHER MANUFACTURERS AND CAN BE USED, AS LONG AS THE COMPLETE SYSTEM AND MANUFACTURER'S PROCEDURES ARE FOLLOWED. Please furnish your body shop foreman and/or painter with this information. REPAIR PROCEDURE 1. The panel that contains the paint cracks must be sanded to the primer surface. NOTE: IN MOST CASES, THE CRACKS ARE LIMITED TO THE TOP CLEAR COAT AND BASE COLOR COAT. CARE SHOULD BE TAKEN NOT TO SAND OR STRIP PAST THE PRIMER SURFACE UNLESS THE CRACKS GO THROUGH THE PRIMER. DOING SO WILL REMOVE THE ORIGINAL COATING APPLIED FOR RUST PROTECTION. 2. Any areas sanded or chemically stripped to metal must be treated with Galvo Prep - DX 520, or equivalent, and primed with DP 40 Epoxy Chromate Primer, or equivalent. 3. The entire panel must then be primed with a two-component primer surfacer (K 200 - part "A" and K 201 - part B, or equivalent). 4. The entire surface must then be scuff sanded. 5. The panel should then be top coated with the appropriate DBU base color coat and DAU 82 or DBU 88 clear coat, or equivalent. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Use of the following Labor Operation will require Zone authorization. 23-77-93-00 . . . . . . . . Actual Time (A/T) FAILURE CODE: P3 - Checking or Cracking Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 231784 > Sep > 84 > Paint - Codes/Cross References/Applications Technical Service Bulletin # 231784 Date: 840924 Paint - Codes/Cross References/Applications Models All 1985 Domestic & Import Passenger Cars & Trucks Subject 1985 Standard Colors Index BODY Date September 24, 1984 No.. 23-17-84 P-4100-C The attached sheets list the Chrysler paint codes which are located on the vehicle body code plate. For location of the code plate see the parts or service manual. The first three spaces on the second line designates whether the vehicle is monotone, two-tone car, or two-tone truck. APA - Monotone APB - Two-Tone Car APC - Two-Tone Truck The next four spaces will be used to designate primary paint color (for 1985 only three spaces will be used). The first letter will always be a "P". The next four spaces will be used to designate secondary paint color (for 1985 only three spaces will be used). The first letter will always be a "Q". In both cases the additional letter and digit will correspond to the letter and digit on the following sheets. These sheets cover all domestic and import cars and trucks for 1985. Various paint manufacturers reference paint codes can be found listed to the right of the Chrysler code. These paint manufacturers have service representatives who are thoroughly experienced in the latest refinishing processes and painting techniques, who can assist your body shop personnel with recommended preparation and application procedures. Color chip charts are available from the respective vendors through their local outlets or service representatives. NOTE: PLEASE FURNISH YOUR BODY SHOP FOREMAN AND/OR PAINTER WITH THIS INFORMATION. POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 231784 > Sep > 84 > Paint - Codes/Cross References/Applications > Page 4126 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 231784 > Sep > 84 > Paint - Codes/Cross References/Applications > Page 4127 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 231784 > Sep > 84 > Paint - Codes/Cross References/Applications > Page 4128 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 231784 > Sep > 84 > Paint - Codes/Cross References/Applications > Page 4129 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 231784 > Sep > 84 > Paint - Codes/Cross References/Applications > Page 4130 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 230291 > Feb > 91 > Paint - Variance Program Paint: All Technical Service Bulletins Paint - Variance Program SUBJECT: Color Variance Program NO.: 23-02-91 GROUP: BODY DATE: Feb. 11, 1991 MODELS: 1984 - 1991 All Domestic Models DISCUSSION: The color variance charts from BASF, Sherwin-Williams, Martin Senour, Acme and Rogers are being sent for use in solving off-color paint problems. The variance charts provide an alternate color that will help the painter achieve a good match or a closer match than the factory pack. Other manufacturers have paint variance programs available that are in a format not suitable for mailing with a bulletin. Check with your local jobber. POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 231784 > Sep > 84 > Paint - Codes/Cross References/Applications Technical Service Bulletin # 231784 Date: 840924 Paint - Codes/Cross References/Applications Models All 1985 Domestic & Import Passenger Cars & Trucks Subject 1985 Standard Colors Index BODY Date September 24, 1984 No.. 23-17-84 P-4100-C The attached sheets list the Chrysler paint codes which are located on the vehicle body code plate. For location of the code plate see the parts or service manual. The first three spaces on the second line designates whether the vehicle is monotone, two-tone car, or two-tone truck. APA - Monotone APB - Two-Tone Car APC - Two-Tone Truck The next four spaces will be used to designate primary paint color (for 1985 only three spaces will be used). The first letter will always be a "P". The next four spaces will be used to designate secondary paint color (for 1985 only three spaces will be used). The first letter will always be a "Q". In both cases the additional letter and digit will correspond to the letter and digit on the following sheets. These sheets cover all domestic and import cars and trucks for 1985. Various paint manufacturers reference paint codes can be found listed to the right of the Chrysler code. These paint manufacturers have service representatives who are thoroughly experienced in the latest refinishing processes and painting techniques, who can assist your body shop personnel with recommended preparation and application procedures. Color chip charts are available from the respective vendors through their local outlets or service representatives. NOTE: PLEASE FURNISH YOUR BODY SHOP FOREMAN AND/OR PAINTER WITH THIS INFORMATION. POLICY: Information only Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 231784 > Sep > 84 > Paint - Codes/Cross References/Applications > Page 4140 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 231784 > Sep > 84 > Paint - Codes/Cross References/Applications > Page 4141 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 231784 > Sep > 84 > Paint - Codes/Cross References/Applications > Page 4142 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 231784 > Sep > 84 > Paint - Codes/Cross References/Applications > Page 4143 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 231784 > Sep > 84 > Paint - Codes/Cross References/Applications > Page 4144 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 4145 Paint: By Symptom Technical Service Bulletin # 231187 Date: 870831 Piant - Small Cracks Visible Models 1985-1987 "L", "P", "H", "K"', "G", "D", "W" & "N" Body Subject "Crows Foot" Shaped Paint Cracking Index BODY Date August 31, 1987 No. 23-11-87 (C9-23) P-3095 FIGURE 1 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 4146 SYMPTOM/CONDITION Vehicles with darker colors may exhibit small cracks in the paint surface. The cracks start from a center point and branch out, normally with three to five lines resembling a "crows foot" (Figure 1). Surrounding the "crows foot" shaped cracks may be short straight or "V" shaped cracks (Figure 1). Of the body types listed above, the following bodies are not affected by this condition. Assembly Plant Model Year/ Vehicle Code (Character Body Assembly Plant 11 of VIN) 1985-87 "K" 4 Door Jefferson C 1987 "G" St. Louis I G NOTE: BECAUSE THE AFFECTED VEHICLES WERE ORIGINALLY MANUFACTURED WITH PPG MATERIAL, THE MATERIALS REFERENCED BELOW ARE PPG (FORMERLY DITZLER). EQUIVALENT MATERIALS ARE AVAILABLE THROUGH OTHER MANUFACTURERS AND CAN BE USED, AS LONG AS THE COMPLETE SYSTEM AND MANUFACTURER'S PROCEDURES ARE FOLLOWED. Please furnish your body shop foreman and/or painter with this information. REPAIR PROCEDURE 1. The panel that contains the paint cracks must be sanded to the primer surface. NOTE: IN MOST CASES, THE CRACKS ARE LIMITED TO THE TOP CLEAR COAT AND BASE COLOR COAT. CARE SHOULD BE TAKEN NOT TO SAND OR STRIP PAST THE PRIMER SURFACE UNLESS THE CRACKS GO THROUGH THE PRIMER. DOING SO WILL REMOVE THE ORIGINAL COATING APPLIED FOR RUST PROTECTION. 2. Any areas sanded or chemically stripped to metal must be treated with Galvo Prep - DX 520, or equivalent, and primed with DP 40 Epoxy Chromate Primer, or equivalent. 3. The entire panel must then be primed with a two-component primer surfacer (K 200 - part "A" and K 201 - part B, or equivalent). 4. The entire surface must then be scuff sanded. 5. The panel should then be top coated with the appropriate DBU base color coat and DAU 82 or DBU 88 clear coat, or equivalent. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Use of the following Labor Operation will require Zone authorization. 23-77-93-00 . . . . . . . . Actual Time (A/T) FAILURE CODE: P3 - Checking or Cracking Technical Service Bulletin # 231187 Date: 870831 Piant - Small Cracks Visible Models 1985-1987 "L", "P", "H", "K"', "G", "D", "W" & "N" Body Subject "Crows Foot" Shaped Paint Cracking Index BODY Date August 31, 1987 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 4147 No. 23-11-87 (C9-23) P-3095 FIGURE 1 SYMPTOM/CONDITION Vehicles with darker colors may exhibit small cracks in the paint surface. The cracks start from a center point and branch out, normally with three to five lines resembling a "crows foot" (Figure 1). Surrounding the "crows foot" shaped cracks may be short straight or "V" shaped cracks (Figure 1). Of the body types listed above, the following bodies are not affected by this condition. Assembly Plant Model Year/ Vehicle Code (Character Body Assembly Plant 11 of VIN) 1985-87 "K" 4 Door Jefferson C 1987 "G" St. Louis I G NOTE: BECAUSE THE AFFECTED VEHICLES WERE ORIGINALLY MANUFACTURED WITH PPG MATERIAL, THE MATERIALS REFERENCED BELOW ARE PPG (FORMERLY DITZLER). EQUIVALENT MATERIALS ARE AVAILABLE THROUGH OTHER MANUFACTURERS AND CAN BE USED, AS LONG AS THE COMPLETE SYSTEM AND MANUFACTURER'S PROCEDURES ARE FOLLOWED. Please furnish your body shop foreman and/or painter with this information. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 4148 REPAIR PROCEDURE 1. The panel that contains the paint cracks must be sanded to the primer surface. NOTE: IN MOST CASES, THE CRACKS ARE LIMITED TO THE TOP CLEAR COAT AND BASE COLOR COAT. CARE SHOULD BE TAKEN NOT TO SAND OR STRIP PAST THE PRIMER SURFACE UNLESS THE CRACKS GO THROUGH THE PRIMER. DOING SO WILL REMOVE THE ORIGINAL COATING APPLIED FOR RUST PROTECTION. 2. Any areas sanded or chemically stripped to metal must be treated with Galvo Prep - DX 520, or equivalent, and primed with DP 40 Epoxy Chromate Primer, or equivalent. 3. The entire panel must then be primed with a two-component primer surfacer (K 200 - part "A" and K 201 - part B, or equivalent). 4. The entire surface must then be scuff sanded. 5. The panel should then be top coated with the appropriate DBU base color coat and DAU 82 or DBU 88 clear coat, or equivalent. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Use of the following Labor Operation will require Zone authorization. 23-77-93-00 . . . . . . . . Actual Time (A/T) FAILURE CODE: P3 - Checking or Cracking Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Door Lock Relay Location Power Door Lock Relay: Locations Door Lock Relay Location Door Lock And Power Window Circuit Breaker And Relays Location The relay is located behind the dash panel, to the left of the glove box. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Door Lock Relay Location > Page 4154 Power Door Lock Relay: Locations Electric Door Lock Relays Electric Door Lock Relay Location. Behind LH Side Of I/P Applicable to: 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 4155 Power Door Lock Relay: Testing and Inspection To test the relay, move either of the front lock knobs to the lock and unlock positions. An audible clicking sound should be heard from under the dash near the steering column support. If the sound is heard while operating one knob but not the other, a defective switch or wiring may be at fault. If a clicking sound is not heard, locate the relay and test as follows: 1. Check for power by back probing the LG wire at the relay. ^ If power is present, go to step 2. ^ If power is not present, check the circuit breaker and the wire between the relay and the circuit breaker. 2. Back probe the OR wire at the relay and move the lock knob to the lock position. Battery voltage should be momentarily present, indicating that the relay operates in the lock position. ^ If power is present go to step 4. ^ If power is not present, go to step 3. 3. Backprobe the VT wire and move the lock knob to the lock position. ^ If power is present, the relay is defective. ^ If power is not present, the door switch or wiring may be defective. 4. Backprobe the LB wire at the relay and move the lock knob to the unlock position. Battery voltage should be momentarily present, indicating that the relay operates in the unlock position. ^ If power is present, the relay is operating properly. ^ If power is not present, go to step 5. 5. Backprobe the LG wire and move the lock knob to the unlock position. ^ If power is present, the relay is defective. ^ If power is not present, the door switch or wiring may be defective. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations > Page 4156 Power Door Lock Relay: Service and Repair Door Lock And Power Window Circuit Breaker And Relays Location Disconnect the battery negative terminal. Remove the wire connector from the relay. Remove the attaching bolt that holds the relay to the instrument panel. Install by attaching relay to the instrument panel and connecting the wires to the relay. Connect the battery negative terminal and test the system for proper operation. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Customer Interest for Seat Cushion: > 231585 > Oct > 85 > Bench Seat Cushion - Not Firm or Collapses Seat Cushion: Customer Interest Bench Seat Cushion - Not Firm or Collapses Models 1985 Conventional Cab Truck With Bench Seat Subject Lack of Firmness or Cushion Collapse Index BODY Date October 7, 1985 No. 23-15-85 SYMPTOM/CONDITION Customer complaints of lack of firmness, pad deterioration or cushion collapse, after a very short time or very low mileage on subject model vehicles, built between October, 1984 and the end of February, 1985, can be resolved by replacing the seat cushion pad. PARTS REQUIRED 1 - Seat Cushion Pad PN 4211581 REPAIR PROCEDURE 1. Shift seat to most forward position. 2. Remove seat back pivot arm side covers and pivot bolts. 3. Lifting seat back lock latch, remove seat back assembly from vehicle. 4. From under vehicle, remove four seat track mounting nuts and remove seat cushion assembly from vehicle. 5. Remove all trim cover retaining hog rings from underside of cushion assembly and remove trim cover and cushion pad from cushion frame. NOTE: IT MAY BE NECESSARY TO LOOSEN THE SEAT BACK STOP BRACKETS ON EACH SIDE OF CUSHION FRAME. 6. Position new cushion on bench with bottom side up, position cushion frame and backing board over cushion pad. Hog ring rear cushion pad attachment wire to cushion frame grid bars. 7. Turn cushion pad and frame assembly upright. Carefully position trim cover over cushion pad and frame assembly. 8. Roll cushion pad, frame and trim cover upside down and hog ring trim cover to grid bars on underside of cushion assembly. NOTE: INSTALL HOG RINGS FROM CENTER OF CUSHION OUT TO ENDS AT REAR OF TRIM COVER FIRST, THEN AT FRONT OF COVER IN THE SAME MANNER AND THEN THE ENDS. (THIS WILL HELP TO MINIMIZE WRINKLING OF THE COVER). 9. Tighten seat back stop brackets. 10. Position seat in vehicle and install and tighten the four mounting nuts. 11. Position seat back to frame and install and tighten pivot bolts. Install seat pivot arm side covers. 12. Verify seat operation. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Refer to Labor Operation Time Schedule for operation and time. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > Customer Interest for Seat Cushion: > 231585 > Oct > 85 > Bench Seat Cushion - Not Firm or Collapses > Page 4166 FAILURE CODE: 20 - Collapsed Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cushion: > 231585 > Oct > 85 > Bench Seat Cushion - Not Firm or Collapses Seat Cushion: All Technical Service Bulletins Bench Seat Cushion - Not Firm or Collapses Models 1985 Conventional Cab Truck With Bench Seat Subject Lack of Firmness or Cushion Collapse Index BODY Date October 7, 1985 No. 23-15-85 SYMPTOM/CONDITION Customer complaints of lack of firmness, pad deterioration or cushion collapse, after a very short time or very low mileage on subject model vehicles, built between October, 1984 and the end of February, 1985, can be resolved by replacing the seat cushion pad. PARTS REQUIRED 1 - Seat Cushion Pad PN 4211581 REPAIR PROCEDURE 1. Shift seat to most forward position. 2. Remove seat back pivot arm side covers and pivot bolts. 3. Lifting seat back lock latch, remove seat back assembly from vehicle. 4. From under vehicle, remove four seat track mounting nuts and remove seat cushion assembly from vehicle. 5. Remove all trim cover retaining hog rings from underside of cushion assembly and remove trim cover and cushion pad from cushion frame. NOTE: IT MAY BE NECESSARY TO LOOSEN THE SEAT BACK STOP BRACKETS ON EACH SIDE OF CUSHION FRAME. 6. Position new cushion on bench with bottom side up, position cushion frame and backing board over cushion pad. Hog ring rear cushion pad attachment wire to cushion frame grid bars. 7. Turn cushion pad and frame assembly upright. Carefully position trim cover over cushion pad and frame assembly. 8. Roll cushion pad, frame and trim cover upside down and hog ring trim cover to grid bars on underside of cushion assembly. NOTE: INSTALL HOG RINGS FROM CENTER OF CUSHION OUT TO ENDS AT REAR OF TRIM COVER FIRST, THEN AT FRONT OF COVER IN THE SAME MANNER AND THEN THE ENDS. (THIS WILL HELP TO MINIMIZE WRINKLING OF THE COVER). 9. Tighten seat back stop brackets. 10. Position seat in vehicle and install and tighten the four mounting nuts. 11. Position seat back to frame and install and tighten pivot bolts. Install seat pivot arm side covers. 12. Verify seat operation. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Refer to Labor Operation Time Schedule for operation and time. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Cushion: > 231585 > Oct > 85 > Bench Seat Cushion - Not Firm or Collapses > Page 4172 FAILURE CODE: 20 - Collapsed Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Lock Switch <--> [Power Door Lock Switch] > Component Information > Locations Door Lock Switch: Locations Power Door Lock Equipment The door switch is located inside each of the front doors, just above the access opening. It is riveted to the inner door panel and has connecting rods to the lock knob and the door latch. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Lock Switch <--> [Power Door Lock Switch] > Component Information > Locations > Page 4177 Door Lock Switch: Testing and Inspection NOTE: The door switches are available only on the front doors. Remove the door trim to gain access to the door switch. Power Door Lock Equipment Unplug the door switch connector and connect an ohmmeter between the center terminal and one of the outer terminals of the door switch. Move the lock knob between the lock and unlock positions several times. The ohmmeter should show continuity (zero resistance) in only one of the positions. Connect the ohmmeter between the center terminal and the other outer terminal and repeat the lock knob movement. The ohmmeter should now show continuity Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Lock Switch <--> [Power Door Lock Switch] > Component Information > Locations > Page 4178 (zero resistance) in the other lock knob position. If the door switch does not test properly, it is defective. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Lock Switch <--> [Power Door Lock Switch] > Component Information > Locations > Page 4179 Door Lock Switch: Service and Repair Remove the battery negative cable. Remove door trim and panel(s) Power Door Lock Equipment Disconnect wire plug from door switch. Disconnect lock knob rod retaining clip and remove lock knob rod from door switch. Disconnect retaining clip on link between latch assembly and door switch. Center punch door switch mounting rivet and drill out rivet head. Install new door switch using either a new rivet or a matching nut, bolt, and washer assembly. Install link between latch assembly and door switch. Install lock knob rod to door switch. Connect wire plug to door switch. Install battery negative cable and test power door lock system. Install door trim panel(s). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest: > 236394 > Aug > 94 > Cowl - Creaking/Popping Sounds Cowl: Customer Interest Cowl - Creaking/Popping Sounds NO: 23-63-94 GROUP: Body EFFECTIVE DATE: Aug. 26, 1994 SUBJECT: Cowl Cracks MODELS: 1993 and Prior (AD) Ram Truck/Ramcharger SYMPTOM/CONDITION: Cracking or popping sounds coming from the cowl area at the lower corners of the windshield. DIAGNOSIS: Inspect the area underneath the fender at the cowl welds. The fenders must be removed to see the cracks. If cracks are present, perform the repair procedure (See Illustration). PARTS REQUIRED: AR 4797018 Cowl Reinforcement-Left AR 4797019 Cowl Reinforcement-Right 3 4746924 3/16" Structural Rivet 1 3M P/N - 08456 3M Panel Adhesive Compound 30 1 3M P/N - 08198 Applicator Gun 1 3M P/N - 08193 Applicator Nozzle REPAIR PROCEDURE: This bulletin involves repairing the cracks and installing a reinforcement. 1. Remove the wiper arms. 2. Remove the cowl screen. 3. Remove the hood with the hood hinges attached. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest: > 236394 > Aug > 94 > Cowl - Creaking/Popping Sounds > Page 4189 4. Remove the front fender or fenders. 5. Drill stop the crack ends with a 1/16" drill. 6. Grind any rough edges from the area where the reinforcement will be secured. Grind the surface of the area to provide a good surface for the adhesive to adhere. 7. Grind the inside surface of the patch. 8. Grind away any paint from the vertical seam to prepare for application of adhesive (See Illustration) and clean the area with a solvent such as Mopar Super Kleen, P/N 4318015. 9. Clean the cowl and the reinforcement with a solvent such as Mopar Super Kleen, P/N 4318015. 10. Assemble the adhesive cartridge to the applicator gun following the manufacturers instructions. 11. Apply adhesive to the cowl approximately 1/16" thick and apply a bead to the vertical seam as shown. 12. Position the patch on the cowl. 13. Drill the 3/16" holes in the cowl and install the rivets, one at a time, until the patch is secure. Clean any excess adhesive from around the reinforcement. 14. Allow 4 hours for the epoxy to cure. 15. Prime the area and apply a coating of rustproofing to minimize corrosion. 16. Seal the panel joint seam at the windshield gasket with RTV to prevent leaks (See Illustration). 17. Install the fender and hood. 18. Install the cowl screen and wiper arms. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 23-00-27-90 (One Side) 3.6 Hrs. 23-00-27-91 (Both Sides 6.0 Hrs. FAILURE CODE: XX - Service Adjustment Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 236394 > Aug > 94 > Cowl - Creaking/Popping Sounds Cowl: All Technical Service Bulletins Cowl - Creaking/Popping Sounds NO: 23-63-94 GROUP: Body EFFECTIVE DATE: Aug. 26, 1994 SUBJECT: Cowl Cracks MODELS: 1993 and Prior (AD) Ram Truck/Ramcharger SYMPTOM/CONDITION: Cracking or popping sounds coming from the cowl area at the lower corners of the windshield. DIAGNOSIS: Inspect the area underneath the fender at the cowl welds. The fenders must be removed to see the cracks. If cracks are present, perform the repair procedure (See Illustration). PARTS REQUIRED: AR 4797018 Cowl Reinforcement-Left AR 4797019 Cowl Reinforcement-Right 3 4746924 3/16" Structural Rivet 1 3M P/N - 08456 3M Panel Adhesive Compound 30 1 3M P/N - 08198 Applicator Gun 1 3M P/N - 08193 Applicator Nozzle REPAIR PROCEDURE: This bulletin involves repairing the cracks and installing a reinforcement. 1. Remove the wiper arms. 2. Remove the cowl screen. 3. Remove the hood with the hood hinges attached. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 236394 > Aug > 94 > Cowl - Creaking/Popping Sounds > Page 4195 4. Remove the front fender or fenders. 5. Drill stop the crack ends with a 1/16" drill. 6. Grind any rough edges from the area where the reinforcement will be secured. Grind the surface of the area to provide a good surface for the adhesive to adhere. 7. Grind the inside surface of the patch. 8. Grind away any paint from the vertical seam to prepare for application of adhesive (See Illustration) and clean the area with a solvent such as Mopar Super Kleen, P/N 4318015. 9. Clean the cowl and the reinforcement with a solvent such as Mopar Super Kleen, P/N 4318015. 10. Assemble the adhesive cartridge to the applicator gun following the manufacturers instructions. 11. Apply adhesive to the cowl approximately 1/16" thick and apply a bead to the vertical seam as shown. 12. Position the patch on the cowl. 13. Drill the 3/16" holes in the cowl and install the rivets, one at a time, until the patch is secure. Clean any excess adhesive from around the reinforcement. 14. Allow 4 hours for the epoxy to cure. 15. Prime the area and apply a coating of rustproofing to minimize corrosion. 16. Seal the panel joint seam at the windshield gasket with RTV to prevent leaks (See Illustration). 17. Install the fender and hood. 18. Install the cowl screen and wiper arms. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No. 23-00-27-90 (One Side) 3.6 Hrs. 23-00-27-91 (Both Sides 6.0 Hrs. FAILURE CODE: XX - Service Adjustment Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cowl: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Diagram Information and Instructions Brake Switch (Cruise Control): Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Diagram Information and Instructions > Page 4211 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Diagram Information and Instructions > Page 4212 Brake Switch (Cruise Control): Electrical Diagrams Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 1 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Diagram Information and Instructions > Page 4213 Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 2 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Diagram Information and Instructions > Page 4214 Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 3 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 4215 Brake Switch (Cruise Control): Testing and Inspection Refer to Speed Control Wiring Diagrams. Prior to performing any tests, ensure servo or valve body and electronic module are properly tested. Fig. 2 Speed control wiring diagram. 1980-84 Vans, Wagons & Front Sections Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 4216 Fig. 3 Speed control wiring diagram. 1981-84 Ramcharger, Trail Duster & Conventional Cabs Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 4217 Fig. 4 Speed control wiring diagram. 1982-84 Rampage & 1983 Scamp Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 4218 Fig. 5 Speed control wiring diagram. 1984 Mini-Vans/Wagons (1985 similar) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 4219 Fig. 6 Speed control wiring diagram. 1985 Conventional Cabs & Ramcharger Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 4220 Fig. 7 Speed control wiring diagram. 1985 rear wheel drive Ram Van & Wagons Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 4221 Fig. 8 Speed control wiring diagram. 1986-87 Conventional Cabs & Ramchargers Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 4222 Fig. 9 Speed control wiring diagram. 1986 rear wheel drive Ram Van & Wagons Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 4223 Fig. 10 Speed control wiring diagram. 1986 Mini-Vans/Wagons Exc. 1986-87 Mini-Vans/Wagons 1. Disconnect double connector at switch pigtail, then connect a suitable 12 volt power source to either terminal. 2. Connect a suitable test lamp to other terminal and ground. Test lamp should illuminate when brake pedal is in normal position and go off when brake pedal is depressed 1/2 - 3/8 inch maximum. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations Clutch Switch: Locations On Clutch Pedal Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 4227 Clutch Switch: Testing and Inspection Clutch Switch Test (Manual Transmission Only) Refer to Speed Control Wiring Diagrams. Prior to performing any tests, ensure servo or valve body and electronic module are properly tested. Fig. 2 Speed control wiring diagram. 1980-84 Vans, Wagons & Front Sections Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 4228 Fig. 3 Speed control wiring diagram. 1981-84 Ramcharger, Trail Duster & Conventional Cabs Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 4229 Fig. 4 Speed control wiring diagram. 1982-84 Rampage & 1983 Scamp Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 4230 Fig. 5 Speed control wiring diagram. 1984 Mini-Vans/Wagons (1985 similar) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 4231 Fig. 6 Speed control wiring diagram. 1985 Conventional Cabs & Ramcharger Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 4232 Fig. 7 Speed control wiring diagram. 1985 rear wheel drive Ram Van & Wagons Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 4233 Fig. 8 Speed control wiring diagram. 1986-87 Conventional Cabs & Ramchargers Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 4234 Fig. 9 Speed control wiring diagram. 1986 rear wheel drive Ram Van & Wagons Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 4235 Fig. 10 Speed control wiring diagram. 1986 Mini-Vans/Wagons Exc. 1986-87 Mini-Vans/Wagons 1. Disconnect double connector at switch pigtail, then connect a 12 volt power source to either end of switch terminal. 2. Connect a suitable test light to remaining terminal end and ground. 3. Test light should be "on" when pedal is in normal position and "off" when pedal is depressed. 4. If above step is not as specified, replace clutch switch. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations Speed Control System Components LH Side Of Engine Compartment Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information > Testing and Inspection Speed Control Servo: Testing and Inspection Refer to Speed Control Wiring Diagrams. Prior to performing any tests, ensure servo or valve body and electronic module are properly tested. Fig. 2 Speed control wiring diagram. 1980-84 Vans, Wagons & Front Sections Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information > Testing and Inspection > Page 4242 Fig. 3 Speed control wiring diagram. 1981-84 Ramcharger, Trail Duster & Conventional Cabs Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information > Testing and Inspection > Page 4243 Fig. 4 Speed control wiring diagram. 1982-84 Rampage & 1983 Scamp Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information > Testing and Inspection > Page 4244 Fig. 5 Speed control wiring diagram. 1984 Mini-Vans/Wagons (1985 similar) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information > Testing and Inspection > Page 4245 Fig. 6 Speed control wiring diagram. 1985 Conventional Cabs & Ramcharger Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information > Testing and Inspection > Page 4246 Fig. 7 Speed control wiring diagram. 1985 rear wheel drive Ram Van & Wagons Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information > Testing and Inspection > Page 4247 Fig. 8 Speed control wiring diagram. 1986-87 Conventional Cabs & Ramchargers Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information > Testing and Inspection > Page 4248 Fig. 9 Speed control wiring diagram. 1986 rear wheel drive Ram Van & Wagons Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information > Testing and Inspection > Page 4249 Fig. 10 Speed control wiring diagram. 1986 Mini-Vans/Wagons Fig. 83 Servo Terminal Electrical Connections Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information > Testing and Inspection > Page 4250 1983-87 REAR WHEEL DRIVE MODELS 1. Connect a suitable test lamp between yellow wire and ground, then proceed as follows: a. Place speed control switch and ignition switch in "On" position. Test lamp should illuminate. b. Depress "Set" button. Test lamp should go out and a clicking noise should be heard at servo. c. Release "Set" button. Test light should illuminate and another click should be heard at servo. d. If test results are not satisfactory, possible causes may be a blown fuse, faulty wiring or defective speed control switch or servo. 2. Connect a suitable test lamp between white wire and ground, then proceed as follows: a. Place speed control switch and ignition switch in "On" position. Test lamp should be off. b. Depress "Set" button. Test lamp should illuminate. c. If test results are not satisfactory, possible causes may be faulty wiring or defective speed control switch. 3. Connect a suitable test lamp between dark blue wire and ground, then proceed as follows: a. Place speed control switch and ignition switch in "On" position. Test lamp should illuminate. b. If test result is not satisfactory, possible causes may be faulty wiring or defective brake, clutch, or speed control switches. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Speed Control Servo <--> [Cruise Control Servo] > Component Information > Testing and Inspection > Page 4251 Speed Control Servo: Service and Repair 1983-87 REAR WHEEL DRIVE MODELS 1. Disconnect speedometer cables and vacuum hose at servo. 2. Disconnect electrical connectors, then remove the two attaching screws. 3. Pull servo away from mounting bracket, then the speed control cable away from servo to expose retaining clip. 4. Remove retaining clip. 5. Reverse procedure to install. Align hole in cable sleeve with hole in servo pin, then insert retaining clip. Torque attaching screws to 80 inch lbs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair > Servo to Carburetor Cable Assembly Replacement Cruise Control Servo Cable: Service and Repair Servo to Carburetor Cable Assembly Replacement 1. Remove air cleaner assembly. 2. Disconnect cable at retaining clamp: a. On front wheel drive models, disconnect cable at carburetor stud by removing spring clip. b. On rear wheel drive models, disconnect cable at carburetor lost motion link by removing spring clip. 3. Disconnect cable at servo and remove cable assembly. 4. Reverse procedure to install. Leave nut loose and adjust throttle cable free play. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair > Servo to Carburetor Cable Assembly Replacement > Page 4256 Fig. 16 Speed control cable installation. 1980-87 Ramcharger, Trail Duster & Conventional Cabs Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection Speed Control Switch: Testing and Inspection Refer to Speed Control Wiring Diagrams. Prior to performing any tests, ensure servo or valve body and electronic module are properly tested. Fig. 2 Speed control wiring diagram. 1980-84 Vans, Wagons & Front Sections Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 4260 Fig. 3 Speed control wiring diagram. 1981-84 Ramcharger, Trail Duster & Conventional Cabs Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 4261 Fig. 4 Speed control wiring diagram. 1982-84 Rampage & 1983 Scamp Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 4262 Fig. 5 Speed control wiring diagram. 1984 Mini-Vans/Wagons (1985 similar) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 4263 Fig. 6 Speed control wiring diagram. 1985 Conventional Cabs & Ramcharger Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 4264 Fig. 7 Speed control wiring diagram. 1985 rear wheel drive Ram Van & Wagons Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 4265 Fig. 8 Speed control wiring diagram. 1986-87 Conventional Cabs & Ramchargers Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 4266 Fig. 9 Speed control wiring diagram. 1986 rear wheel drive Ram Van & Wagons Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 4267 Fig. 10 Speed control wiring diagram. 1986 Mini-Vans/Wagons Rear Wheel Drive Models 1. Check fuse for continuity. 2. Disconnect four wire electrical connector at steering column. 3. Connect a suitable 12 volt power source to black wire terminal of switch harness connector. 4. Attach one lead of a suitable test lamp to ground, then attach the second lead to yellow wire terminal. Test lamp should illuminate with speed control switch in "on" position. Test lamp should be off when set button is depressed, or when speed control switch is in "off" position. 5. Attach test lamp lead to dark blue wire. Test lamp should illuminate with slide switch in "on" position and be off with slide switch in "off" position. 6. Attach test lead to white wire. Test lamp should be off with slide switch in "on" position, illuminate when set button is depressed, and be off when switch is released. Test lamp should illuminate when slide switch is moved to "Resume" position, and go off when slide switch is released. 7. Replace speed control switch if test lamp does not respond as indicated. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 4268 Front Wheel Drive Models, Exc. 1986-87 Mini-Vans/Wagons 1. Check fuse for continuity. 2. Disconnect four wire electrical connector at steering column. 3. Connect a suitable 12 volt power source to yellow wire terminal of switch harness connector. 4. Attach one lead of a suitable test lamp to ground, then the second lead to brown wire with red tracer terminal test lamp should illuminate with speed control switch in "on" position. Test lamp should be off when set button is depressed, or when speed control switch is in "off" position. 5. Attach test lamp lead to dark blue wire with white tracer. Test lamp should illuminate with slide switch in "on" position, and be off with slide switch in "off" position. 6. Attach test lead to white wire with red tracer. Test lamp should be off with slide switch in "on" position, illuminate when set button is depressed, and be off when switch is released. Test lamp should illuminate when slide switch is moved to "Resume" position, then go off when slide switch is released. 7. Replace speed control switch if test lamp does not respond as indicated. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 4269 Speed Control Switch: Service and Repair Fig. 22 Removing wire terminals REAR WHEEL DRIVE MODELS 1. Disconnect battery ground cable. 2. Disconnect speed control connector at lower end of column. 3. Remove steering wheel. 4. Remove turn signal switch, then the lever attaching screws. 5. Remove steering column cover plate to gain access to lead wires at lower end of switch, then remove wires and terminals from connector using tool No. C-4135 or equivalent. 6. Tape terminals, then remove lever and wires. 7. Reverse procedure to install. A guide wire will be required to install wiring harness of new speed control switch through steering column opening. On tilt or telescopic steering columns, insert guide wire through turn signal lever opening in column. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations Speed Control System Components LH Side Of Engine Compartment Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Diagram Information and Instructions Brake Switch (Cruise Control): Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Diagram Information and Instructions > Page 4279 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Diagram Information and Instructions > Page 4280 Brake Switch (Cruise Control): Electrical Diagrams Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 1 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Diagram Information and Instructions > Page 4281 Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 2 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Diagram Information and Instructions > Page 4282 Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 3 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 4283 Brake Switch (Cruise Control): Testing and Inspection Refer to Speed Control Wiring Diagrams. Prior to performing any tests, ensure servo or valve body and electronic module are properly tested. Fig. 2 Speed control wiring diagram. 1980-84 Vans, Wagons & Front Sections Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 4284 Fig. 3 Speed control wiring diagram. 1981-84 Ramcharger, Trail Duster & Conventional Cabs Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 4285 Fig. 4 Speed control wiring diagram. 1982-84 Rampage & 1983 Scamp Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 4286 Fig. 5 Speed control wiring diagram. 1984 Mini-Vans/Wagons (1985 similar) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 4287 Fig. 6 Speed control wiring diagram. 1985 Conventional Cabs & Ramcharger Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 4288 Fig. 7 Speed control wiring diagram. 1985 rear wheel drive Ram Van & Wagons Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 4289 Fig. 8 Speed control wiring diagram. 1986-87 Conventional Cabs & Ramchargers Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 4290 Fig. 9 Speed control wiring diagram. 1986 rear wheel drive Ram Van & Wagons Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Diagrams > Page 4291 Fig. 10 Speed control wiring diagram. 1986 Mini-Vans/Wagons Exc. 1986-87 Mini-Vans/Wagons 1. Disconnect double connector at switch pigtail, then connect a suitable 12 volt power source to either terminal. 2. Connect a suitable test lamp to other terminal and ground. Test lamp should illuminate when brake pedal is in normal position and go off when brake pedal is depressed 1/2 - 3/8 inch maximum. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations Clutch Switch: Locations On Clutch Pedal Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 4295 Clutch Switch: Testing and Inspection Clutch Switch Test (Manual Transmission Only) Refer to Speed Control Wiring Diagrams. Prior to performing any tests, ensure servo or valve body and electronic module are properly tested. Fig. 2 Speed control wiring diagram. 1980-84 Vans, Wagons & Front Sections Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 4296 Fig. 3 Speed control wiring diagram. 1981-84 Ramcharger, Trail Duster & Conventional Cabs Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 4297 Fig. 4 Speed control wiring diagram. 1982-84 Rampage & 1983 Scamp Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 4298 Fig. 5 Speed control wiring diagram. 1984 Mini-Vans/Wagons (1985 similar) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 4299 Fig. 6 Speed control wiring diagram. 1985 Conventional Cabs & Ramcharger Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 4300 Fig. 7 Speed control wiring diagram. 1985 rear wheel drive Ram Van & Wagons Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 4301 Fig. 8 Speed control wiring diagram. 1986-87 Conventional Cabs & Ramchargers Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 4302 Fig. 9 Speed control wiring diagram. 1986 rear wheel drive Ram Van & Wagons Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page 4303 Fig. 10 Speed control wiring diagram. 1986 Mini-Vans/Wagons Exc. 1986-87 Mini-Vans/Wagons 1. Disconnect double connector at switch pigtail, then connect a 12 volt power source to either end of switch terminal. 2. Connect a suitable test light to remaining terminal end and ground. 3. Test light should be "on" when pedal is in normal position and "off" when pedal is depressed. 4. If above step is not as specified, replace clutch switch. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection Speed Control Switch: Testing and Inspection Refer to Speed Control Wiring Diagrams. Prior to performing any tests, ensure servo or valve body and electronic module are properly tested. Fig. 2 Speed control wiring diagram. 1980-84 Vans, Wagons & Front Sections Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 4307 Fig. 3 Speed control wiring diagram. 1981-84 Ramcharger, Trail Duster & Conventional Cabs Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 4308 Fig. 4 Speed control wiring diagram. 1982-84 Rampage & 1983 Scamp Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 4309 Fig. 5 Speed control wiring diagram. 1984 Mini-Vans/Wagons (1985 similar) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 4310 Fig. 6 Speed control wiring diagram. 1985 Conventional Cabs & Ramcharger Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 4311 Fig. 7 Speed control wiring diagram. 1985 rear wheel drive Ram Van & Wagons Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 4312 Fig. 8 Speed control wiring diagram. 1986-87 Conventional Cabs & Ramchargers Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 4313 Fig. 9 Speed control wiring diagram. 1986 rear wheel drive Ram Van & Wagons Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 4314 Fig. 10 Speed control wiring diagram. 1986 Mini-Vans/Wagons Rear Wheel Drive Models 1. Check fuse for continuity. 2. Disconnect four wire electrical connector at steering column. 3. Connect a suitable 12 volt power source to black wire terminal of switch harness connector. 4. Attach one lead of a suitable test lamp to ground, then attach the second lead to yellow wire terminal. Test lamp should illuminate with speed control switch in "on" position. Test lamp should be off when set button is depressed, or when speed control switch is in "off" position. 5. Attach test lamp lead to dark blue wire. Test lamp should illuminate with slide switch in "on" position and be off with slide switch in "off" position. 6. Attach test lead to white wire. Test lamp should be off with slide switch in "on" position, illuminate when set button is depressed, and be off when switch is released. Test lamp should illuminate when slide switch is moved to "Resume" position, and go off when slide switch is released. 7. Replace speed control switch if test lamp does not respond as indicated. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 4315 Front Wheel Drive Models, Exc. 1986-87 Mini-Vans/Wagons 1. Check fuse for continuity. 2. Disconnect four wire electrical connector at steering column. 3. Connect a suitable 12 volt power source to yellow wire terminal of switch harness connector. 4. Attach one lead of a suitable test lamp to ground, then the second lead to brown wire with red tracer terminal test lamp should illuminate with speed control switch in "on" position. Test lamp should be off when set button is depressed, or when speed control switch is in "off" position. 5. Attach test lamp lead to dark blue wire with white tracer. Test lamp should illuminate with slide switch in "on" position, and be off with slide switch in "off" position. 6. Attach test lead to white wire with red tracer. Test lamp should be off with slide switch in "on" position, illuminate when set button is depressed, and be off when switch is released. Test lamp should illuminate when slide switch is moved to "Resume" position, then go off when slide switch is released. 7. Replace speed control switch if test lamp does not respond as indicated. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Speed Control Switch <--> [Cruise Control Switch] > Component Information > Testing and Inspection > Page 4316 Speed Control Switch: Service and Repair Fig. 22 Removing wire terminals REAR WHEEL DRIVE MODELS 1. Disconnect battery ground cable. 2. Disconnect speed control connector at lower end of column. 3. Remove steering wheel. 4. Remove turn signal switch, then the lever attaching screws. 5. Remove steering column cover plate to gain access to lead wires at lower end of switch, then remove wires and terminals from connector using tool No. C-4135 or equivalent. 6. Tape terminals, then remove lever and wires. 7. Reverse procedure to install. A guide wire will be required to install wiring harness of new speed control switch through steering column opening. On tilt or telescopic steering columns, insert guide wire through turn signal lever opening in column. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Ammeter Gauge > Component Information > Description and Operation Ammeter Gauge: Description and Operation The ammeter is an instrument used to indicate current flow into and out of the battery. When electrical accessories in the vehicle draw more current than the alternator can supply, current flows from the battery, and the ammeter indicates a discharge ( - ) condition. When electrical loads of the vehicle are less than alternator output, current is available to charge the battery, and the ammeter indicates a charge (+) condition. If battery is fully charged, the voltage regulator reduces alternator output to meet only immediate vehicle electrical loads. When this happens, ammeter reads zero. Fig. 1 Typical conventional type ammeter CONVENTIONAL AMMETER A conventional ammeter must be connected between the battery and alternator in order to indicate current flow. This type ammeter consists of a frame to which a permanent magnet is attached. The frame also supports an armature and pointer assembly. Current in this system flows from the alternator through the ammeter, then to the battery or from the battery through the ammeter into the vehicle electrical system, depending on vehicle operating conditions. When no current flows through the ammeter, the magnet holds the pointer armature so that the pointer stands at the center of the dial. When current passes in either direction through the ammeter, the resulting magnetic field attracts the armature away from the effect of the permanent magnet, thus giving a reading proportional to the strength of the current flowing. Troubleshooting When the ammeter apparently fails to register correctly, there may be trouble in the wiring which connects the ammeter to the alternator and battery or in the alternator or battery itself. To check the connections, first tighten the two terminal posts on the back of the ammeter. Then, following each wire from the ammeter, tighten all connections on the ignition switch, battery and alternator. Chafed, burned or broken insulation can be found by following each ammeter wire from end to end. All wires with chafed, burned or broken insulation should be repaired or replaced. After this is done, and all connections are tightened, connect the battery cable and turn on the ignition switch. The needle should point slightly to the discharge ( - ) side. Start the engine and run slightly above idling speed. The needle should move slowly to the charge side (+). If the pointer does not move as indicated, the ammeter is out of order and should be replaced. SHUNT TYPE AMMETER The shunt type ammeter is actually a specifically calibrated voltmeter. If it connected to read voltage drop across a resistance wire (shunt) between the battery and alternator. The shunt is located either in the vehicle wiring or within the ammeter itself. When voltage is higher at the alternator end of the shunt, the meter indicates a charge (+) condition. When voltage is higher at the battery end of the shunt, the meter indicates a discharge ( - ) condition. When voltage is equal at both ends of the shunt, the meter reads zero. Troubleshooting Ammeter accuracy can be determined by comparing reading with an ammeter of known accuracy. 1. With engine stopped and ignition switch in RUN position, switch on headlamps and heater fan. Meter should indicate a discharge ( - ) condition. 2. If ammeter pointer does not move, check ammeter terminals for proper connection and check for open circuit in wiring harness. If connections and wiring harness are satisfactory, ammeter is defective. 3. If ammeter indicates a charge (+) condition, wiring harness connections are reversed at ammeter. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Ammeter Gauge > Component Information > Description and Operation > Page 4321 Ammeter Gauge: Testing and Inspection The ammeter is an instrument used to indicate current flow into and out of the battery. When electrical accessories in the vehicle draw more current than the alternator can supply, current flows from the battery, and the ammeter indicates a discharge ( - ) condition. When electrical loads of the vehicle are less than alternator output, current is available to charge the battery, and the ammeter indicates a charge (+) condition. If battery is fully charged, the voltage regulator reduces alternator output to meet only immediate vehicle electrical loads. When this happens, ammeter reads zero. Fig. 1 Typical conventional type ammeter CONVENTIONAL AMMETER A conventional ammeter must be connected between the battery and alternator in order to indicate current flow. This type ammeter consists of a frame to which a permanent magnet is attached. The frame also supports an armature and pointer assembly. Current in this system flows from the alternator through the ammeter, then to the battery or from the battery through the ammeter into the vehicle electrical system, depending on vehicle operating conditions. When no current flows through the ammeter, the magnet holds the pointer armature so that the pointer stands at the center of the dial. When current passes in either direction through the ammeter, the resulting magnetic field attracts the armature away from the effect of the permanent magnet, thus giving a reading proportional to the strength of the current flowing. Troubleshooting When the ammeter apparently fails to register correctly, there may be trouble in the wiring which connects the ammeter to the alternator and battery or in the alternator or battery itself. To check the connections, first tighten the two terminal posts on the back of the ammeter. Then, following each wire from the ammeter, tighten all connections on the ignition switch, battery and alternator. Chafed, burned or broken insulation can be found by following each ammeter wire from end to end. All wires with chafed, burned or broken insulation should be repaired or replaced. After this is done, and all connections are tightened, connect the battery cable and turn on the ignition switch. The needle should point slightly to the discharge ( - ) side. Start the engine and run slightly above idling speed. The needle should move slowly to the charge side (+). If the pointer does not move as indicated, the ammeter is out of order and should be replaced. SHUNT TYPE AMMETER The shunt type ammeter is actually a specifically calibrated voltmeter. If it connected to read voltage drop across a resistance wire (shunt) between the battery and alternator. The shunt is located either in the vehicle wiring or within the ammeter itself. When voltage is higher at the alternator end of the shunt, the meter indicates a charge (+) condition. When voltage is higher at the battery end of the shunt, the meter indicates a discharge ( - ) condition. When voltage is equal at both ends of the shunt, the meter reads zero. Troubleshooting Ammeter accuracy can be determined by comparing reading with an ammeter of known accuracy. 1. With engine stopped and ignition switch in RUN position, switch on headlamps and heater fan. Meter should indicate a discharge ( - ) condition. 2. If ammeter pointer does not move, check ammeter terminals for proper connection and check for open circuit in wiring harness. If connections and wiring harness are satisfactory, ammeter is defective. 3. If ammeter indicates a charge (+) condition, wiring harness connections are reversed at ammeter. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 4326 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 4327 Fig. 15 Fuel Gauge & Seatbelt Warning System Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 4332 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 4333 Fig. 6 Ash Tray Lamp, Cigar Lighter & Glove Box Lamp Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Technical Service Bulletins > Radio/Clock - Defeat Function Explanation Clock: Technical Service Bulletins Radio/Clock - Defeat Function Explanation Models All 1985 Equipped With Radio Subject Clock Defeat Function Index ELECTRICAL Date February 18, 1985 No.. 08-03-85 P-540-C 1985 vehicles are equipped with radios that have a clock defeat function. The defeat mode is provided to eliminate the clock display whenever the vehicle has other options that contain a clock. Defeat functions operate in the following manner: NOTE: WHENEVER THE BATTERY IS DISCONNECTED FOR ANY REASON, TURN OFF RADIO BEFORE RECONNECTING THE BATTERY. THIS PROCEDURE SHOULD ALSO BE PERFORMED PRIOR TO REMOVING RADIO FOR REPAIR OF AN INOPERATIVE CLOCK. AM FM STEREO Defeat: With the radio ON and time displayed, press the SET button once, then press the volume control knob once and finally, press the AM FM button three times. To restore: Repeat the above procedure. AM STEREO & FM STEREO WITH CASSETTE Defeat: With the radio ON and time displayed, using two fingers, press any one of the six memory buttons and the volume control knob at the same time. Then press the AM FM button three times. To restore: Repeat the above procedure. ULTIMATE SOUND SYSTEM - AM STEREO & FM STEREO WITH CASSETTE To defeat time display: With the radio ON and time displayed, press the SET button once, then press the volume control knob once and finally press the 70 us button twice. To restore the display repeat the above procedure. NOTE: TIME CANNOT BE SET, DEFEATED OR RESTORED WHILE THE TAPE IS PLAYING. Information only. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Technical Service Bulletins > Page 4338 Clock: Description and Operation Regulation of electric clocks is accomplished automatically by resetting the time. If the clock is running fast, the action of turning the hands back to correct the time will automatically cause the clock to run slightly slower. If the clock is running slow, the action of turning the hands forward to correct the time will automatically cause the clock to run slightly faster (10 to 15 seconds day). A lock-out feature prevents the clock regulator mechanism from being reset more than once per wind cycle, regardless of the number of times the time is reset. After the clock rewinds, if the time is then reset, automatic regulation will take place. If a clock varies over 10 minutes per day, it will never adjust properly and must be repaired or replaced. WINDING CLOCK WHEN CONNECTING BATTERY OR CLOCK WIRING The clock requires special attention when reconnecting a battery that has been disconnected for any reason, a clock that has been disconnected, or when replacing a blown clock fuse. It is very important that the initial wind be fully made. The procedure is as follows: 1. Make sure that all other instruments and lights are turned off. 2. Connect positive cable to battery. 3. Before connecting the negative cable, press the terminal to its post on the battery. Immediately afterward, strike the terminal against the battery post to see if there is a spark. If there is a spark, allow the clock to run down until it stops ticking, and repeat as above until there is no spark. Then immediately make the permanent connection before the clock can again run down. The clock will run down in approximately two minutes. 4. Reset clock after all connections have been made. The foregoing procedure should also be followed when reconnecting the clock after it has been disconnected, or if it has stopped because of a blown fuse. Be sure to disconnect battery before installing a new fuse. TROUBLESHOOTING If clock does not run, check for blown "clock" fuse. If fuse is blown, check for short in wiring. If fuse is not blown, check for open circuit. With an electric clock, the most frequent cause of clock fuse blowing is voltage at the clock which will prevent a complete wind and allow clock contacts to remain closed. This may be caused by any of the following: discharged battery, corrosion on contact surface of battery terminals, loose connections at battery terminals, at junction block, at fuse clips, or at terminal connection of clock. Therefore, if in reconnecting battery or clock it is noted that the clock is not ticking, always check for blown fuse, or examine the circuits at the points indicated above to determine and correct the cause. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Technical Service Bulletins > Page 4339 Clock: Testing and Inspection Regulation of electric clocks is accomplished automatically by resetting the time. If the clock is running fast, the action of turning the hands back to correct the time will automatically cause the clock to run slightly slower. If the clock is running slow, the action of turning the hands forward to correct the time will automatically cause the clock to run slightly faster (10 to 15 seconds day). A lock-out feature prevents the clock regulator mechanism from being reset more than once per wind cycle, regardless of the number of times the time is reset. After the clock rewinds, if the time is then reset, automatic regulation will take place. If a clock varies over 10 minutes per day, it will never adjust properly and must be repaired or replaced. WINDING CLOCK WHEN CONNECTING BATTERY OR CLOCK WIRING The clock requires special attention when reconnecting a battery that has been disconnected for any reason, a clock that has been disconnected, or when replacing a blown clock fuse. It is very important that the initial wind be fully made. The procedure is as follows: 1. Make sure that all other instruments and lights are turned off. 2. Connect positive cable to battery. 3. Before connecting the negative cable, press the terminal to its post on the battery. Immediately afterward, strike the terminal against the battery post to see if there is a spark. If there is a spark, allow the clock to run down until it stops ticking, and repeat as above until there is no spark. Then immediately make the permanent connection before the clock can again run down. The clock will run down in approximately two minutes. 4. Reset clock after all connections have been made. The foregoing procedure should also be followed when reconnecting the clock after it has been disconnected, or if it has stopped because of a blown fuse. Be sure to disconnect battery before installing a new fuse. TROUBLESHOOTING If clock does not run, check for blown "clock" fuse. If fuse is blown, check for short in wiring. If fuse is not blown, check for open circuit. With an electric clock, the most frequent cause of clock fuse blowing is voltage at the clock which will prevent a complete wind and allow clock contacts to remain closed. This may be caused by any of the following: discharged battery, corrosion on contact surface of battery terminals, loose connections at battery terminals, at junction block, at fuse clips, or at terminal connection of clock. Therefore, if in reconnecting battery or clock it is noted that the clock is not ticking, always check for blown fuse, or examine the circuits at the points indicated above to determine and correct the cause. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Technical Service Bulletins > Page 4340 Clock: Service and Repair Regulation of electric clocks is accomplished automatically by resetting the time. If the clock is running fast, the action of turning the hands back to correct the time will automatically cause the clock to run slightly slower. If the clock is running slow, the action of turning the hands forward to correct the time will automatically cause the clock to run slightly faster (10 to 15 seconds day). A lock-out feature prevents the clock regulator mechanism from being reset more than once per wind cycle, regardless of the number of times the time is reset. After the clock rewinds, if the time is then reset, automatic regulation will take place. If a clock varies over 10 minutes per day, it will never adjust properly and must be repaired or replaced. WINDING CLOCK WHEN CONNECTING BATTERY OR CLOCK WIRING The clock requires special attention when reconnecting a battery that has been disconnected for any reason, a clock that has been disconnected, or when replacing a blown clock fuse. It is very important that the initial wind be fully made. The procedure is as follows: 1. Make sure that all other instruments and lights are turned off. 2. Connect positive cable to battery. 3. Before connecting the negative cable, press the terminal to its post on the battery. Immediately afterward, strike the terminal against the battery post to see if there is a spark. If there is a spark, allow the clock to run down until it stops ticking, and repeat as above until there is no spark. Then immediately make the permanent connection before the clock can again run down. The clock will run down in approximately two minutes. 4. Reset clock after all connections have been made. The foregoing procedure should also be followed when reconnecting the clock after it has been disconnected, or if it has stopped because of a blown fuse. Be sure to disconnect battery before installing a new fuse. TROUBLESHOOTING If clock does not run, check for blown "clock" fuse. If fuse is blown, check for short in wiring. If fuse is not blown, check for open circuit. With an electric clock, the most frequent cause of clock fuse blowing is voltage at the clock which will prevent a complete wind and allow clock contacts to remain closed. This may be caused by any of the following: discharged battery, corrosion on contact surface of battery terminals, loose connections at battery terminals, at junction block, at fuse clips, or at terminal connection of clock. Therefore, if in reconnecting battery or clock it is noted that the clock is not ticking, always check for blown fuse, or examine the circuits at the points indicated above to determine and correct the cause. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions Door/Trunk Ajar Indicator/Lamp: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4345 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4346 Fig. 27 Liftgate Ajar & Rear Courtesy Lamps Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4351 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4352 Fig. 8 Cargo, Dome & Map Lamps Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Service Reminder Indicator Light <--> [Emissions Maintenance Light] > Emissions Maintenance Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions Emissions Maintenance Lamp Relay: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Service Reminder Indicator Light <--> [Emissions Maintenance Light] > Emissions Maintenance Lamp Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4358 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Indicator Lamp: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4363 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4364 Fig. 14 Four Wheel Drive Indicator Lamp Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation Fuel Gauge: Description and Operation A hinged float arm in the fuel tank contacts a variable resistor in the gauge sending unit. The varying resistance in the fuel gauge circuit registers on the instrument panel gauge. Resistance in the circuit is lowest when the fuel tank is full and float arm is raised. The resulting high current flow causes the instrument panel gauge to indicate Full. TROUBLESHOOTING 1. Disconnect electrical connector from fuel tank sending unit and attach connector to a known good sending unit. 2. Connect a jumper wire between sending unit fuel pickup tube and a good ground. 3. Secure sending unit float arm in the empty stop position and turn ignition On. Within two minutes, the gauge should read Empty, plus one pointer width or minus two pointer widths. 4. Move float arm and secure in the full stop position. Within two minutes, the gauge should read Full, plus two pointer widths, or minus one pointer width. 5. If fuel gauge does not operate as specified, check the following: a. Wiring and electrical connections between sending unit and connector. b. Wiring and electrical connections between connector and printed circuit board terminals. c. Circuit continuity between printed circuit board terminals and gauge terminals. d. Voltage limiter performance. 6. If fuel gauge operates as specified with known good sending unit, check fuel tank and original sending unit as follows: a. Remove sending unit from fuel tank. b. Connect sending unit wire and jumper wire as previously described. c. If fuel gauge now operates as specified, check sending unit for damage, obstructions or improper installation and correct as necessary. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation > Page 4368 Fuel Gauge: Testing and Inspection A hinged float arm in the fuel tank contacts a variable resistor in the gauge sending unit. The varying resistance in the fuel gauge circuit registers on the instrument panel gauge. Resistance in the circuit is lowest when the fuel tank is full and float arm is raised. The resulting high current flow causes the instrument panel gauge to indicate Full. TROUBLESHOOTING 1. Disconnect electrical connector from fuel tank sending unit and attach connector to a known good sending unit. 2. Connect a jumper wire between sending unit fuel pickup tube and a good ground. 3. Secure sending unit float arm in the empty stop position and turn ignition On. Within two minutes, the gauge should read Empty, plus one pointer width or minus two pointer widths. 4. Move float arm and secure in the full stop position. Within two minutes, the gauge should read Full, plus two pointer widths, or minus one pointer width. 5. If fuel gauge does not operate as specified, check the following: a. Wiring and electrical connections between sending unit and connector. b. Wiring and electrical connections between connector and printed circuit board terminals. c. Circuit continuity between printed circuit board terminals and gauge terminals. d. Voltage limiter performance. 6. If fuel gauge operates as specified with known good sending unit, check fuel tank and original sending unit as follows: a. Remove sending unit from fuel tank. b. Connect sending unit wire and jumper wire as previously described. c. If fuel gauge now operates as specified, check sending unit for damage, obstructions or improper installation and correct as necessary. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 4377 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 4378 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 4379 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 4380 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 4381 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 4382 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 4383 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 4384 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 4385 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 4386 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 4387 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 4388 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 4389 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 4390 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System Engine Vapor Lock > Page 4391 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock Technical Service Bulletin # 181985A Date: 851201 Fuel System - Vapor Lock Models 1981-1985 Van & Wagon Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 20, 1985 No. 18-19-85 REVISION A P-4782-C This bulletin supersedes Technical Service Bulletin #18-19-85 which should be removed from your files. The model application has been expanded to include 1981 and 1982 model years. SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING TWO PART NUMBERS: Vapor Lock Package With 22 Gallon Fuel Tank PN 4397611 Vapor Lock Package With 36 Gallon Fuel Tank PN 4397612 ADDITIONAL PARTS INFORMATION ON NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 All vehicles equipped with dual air conditioning, without electrically heated rear window defroster, and with 60 amp alternator must order the following package in addition to the vapor lock package. If vehicle is equipped with a 114 amp alternator, do not order this package or make any changes to the charging system. 1 78 AMP Alternator Package PN 4397615 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4396 Refer to parts list for contents of each package. Must be ordered separately: 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. REPAIR PROCEDURE A.Engine Compartment Harness Pn 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1A - ENGINE COMPARTMENT WIRING 3. Remove engine cover. Install the bare eyelet terminal of overlay harness, PN 4362295, to the negative terminal of the ignition coil as shown in Figure 1-A. FIGURE 1B - ENGINE COMPARTMENT WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4397 4. Route and secure the engine overlay harness, PN 4362295, along the existing main engine wiring harness using the existing wiring clips and two tie wraps, PN 6015756 (Figure 1-B). FIGURE 1C - ENGINE COMPARTMENT WIRING 5. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness to the bulkhead connector using the existing wiring clips and three tie wraps, PN 6015756 (Figure 1-C). Loop and tape any excess wire of the engine overlay harness. FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 6. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar multi-purpose grease PN 4318063, and snap into cavity #14 of the engine side of the bulkhead connector (Figure 1-D). B.Instrument Panel Harnesses Pn 4362289, All Models Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4398 FIGURE 2A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) 1. Remove instrument panel left lower trim panel. 2. Insert two bare terminals from instrument panel overlay harness, PN 4362289, into the instrument panel side of the bulkhead connector (Figure 2-A). a. Gray with black tracer wire into cavity #14. b. Dark green wire into cavity #13. INSTRUMENT PANEL WIRING 3. Secure bare eyelet ground terminal (white with black tracer wire) from instrument panel overlay harness, PN 4362289, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). NOTE: CERTAIN VEHICLES ARE ALREADY EQUIPPED WITH THE GROUND SCREW. IF SO, DISCARD THE SUPPLIED SCREW. FIGURE 2C - INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4399 FIGURE 2D - INSTRUMENT PANEL WIRING 4. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-C). Install the extracted terminal (orange wire) into the natural colored 1-way connector supplied with instrument panel overlay harness, PN 4362289. Install the bare terminal (orange wire) from the instrument panel overlay harness, PN 4362289, into the vacated cavity in the ignition switch connector. Reconnect the natural colored 1-way connectors supplied with the instrument panel overlay harness, PN 4362289, and reconnect the ignition switch connectors (Figure 2-C and 2-D). FIGURE 2E - TYPICAL CONTROL MODULE MOUNTING 5. Connect the control (auto shut-down) module, PN 5226640, to the natural colored 8-way connector from instrument panel overlay harness, PN 4362289. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4400 FIGURE 2D - INSTRUMENT PANEL WIRING FIGURE 2F - INSTRUMENT PANEL WIRING 6. Route the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289, to the back of the brake bracket for mating in a later step (Figures 2-B, 2-D, and 2-F). Secure instrument panel overlay harness, PN 4362289, using tie wrap, PN 6015756, to keep it clear of any possible interferences. Only one of the following installation procedures (Step 7) will be used. Take notice of which one applies to the vehicle being repaired. 7. Without Auxiliary Air Conditioning and/or Heater - Jumper Harness PN 4362291 a. Remove instrument panel hood and bezel assembly and remove radio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4401 FIGURE 2D - INSTRUMENT PANEL WIRING b. Route instrument panel jumper harness, PN 4362291, from the back of the brake bracket to the existing 3-way red molded connector. Secure by using existing wiring clips (Figure 2-D). c. Insert the bare bullet terminal (black with white tracer wire) from instrument panel jumper harness, PN 4362291, into the existing 3-way red molded connector from the main instrument panel wiring harness (Figure 2-D). d. Mate the orange colored 1-way connector from instrument panel jumper harness, PN 4362291, to the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). e. Reinstall instrument panel hood and bezel assembly and install radio. FIGURE 2F - INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater and Power Windows - Jumper Harness PN 4362292 a. Disconnect from each other, the two existing brown colored 1-way connectors located near the left instrument panel vent (Figure 2-F). Reconnect these two brown colored 1-way connectors to the two brown colored 1-way connectors from instrument panel jumper harness, PN 4362292 (Figure 2-F). b. Mate the orange colored 1-way connector from the instrument panel jumper harness, PN 4362292, to the orange colored 1-way connector from instrument panel overlay harness, PN 4362289 (Figure 2-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4402 INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater Without Power Windows - Relay Harness PN 4362290 a. Remove instrument panel hood and bezel assembly. Remove radio. b. Install the ignition switch protection relay, PN 4162597, to the back of the brake bracket (mounting location shown in Figure 2-B) and attach instrument panel relay harness, PN 4362290, to relay. c. Secure bare eyelet ground terminal (white wire) from instrument panel relay harness, PN 4362290, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING d. Route the dark blue wire from the instrument panel relay harness, PN 4362290 to the existing 3-way red molded connector using existing wiring clips. Insert bullet terminal (dark blue wire) into red molded connector (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4403 INSTRUMENT PANEL WIRING e. Insert bare bullet terminal (red wire) from instrument panel relay harness, PN 4362290, into the existing 3-way yellow molded connector from the main instrument panel wiring harness (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING f. Mate the orange colored 1-way connector from instrument panel relay harness, PN 4362290, to the colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). g. Install the instrument panel left lower trim panel, instrument panel hood, bezel assembly and radio. C.In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Feed red and yellow molds of body wiring harness, PN 4362293, through slot in the crossmember. Remove existing screw for gauge unit ground. Install eyelet terminal of harness, PN 4362293 (and ground eyelet terminal of 36 gallon tank gauge/pump unit) and torque ground screw to 36 inch pounds. CAUTION: GROUND SCREW MUST BE TIGHTENED SECURELY TO OPERATE ELECTRIC PUMP AND GAUGE UNIT. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4404 FIGURE 3A - BODY WIRING FIGURE 3B - BODY WIRING Install red mold of body harness, PN 4362293, onto red stud of gauge/pump unit. Install yellow mold of harness, PN 4362293, onto black stud of gauge/pump unit (figure 3-a or 3-b). Install molded blade terminal of harness, PN 4362293, onto blade terminal of 22 gallon gauge unit only. NOTE: PREVIOUS GAUGE UNIT GROUND WILL NOT BE USED ON 22 GALLON GAUGE/PUMP UNIT. ON 36 GALLON GAUGE PUMP UNIT, THE GROUND WIRE ON HARNESS PN 4362293 WILL NOT BE USED. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. Set aside the rest of harness, PN 4362293, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. D.Body Wiring Harness Pn 4362293 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4405 FIGURE 3C - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4406 FIGURE 3-F - BODY WIRING 1. Vehicles With 36 Gallon Tank Route harness, PN 4362293, to the right (passenger) side of vehicle along the fuel line tubes and tie wrap (1). At right frame rail, route harness forward to next crossmember (Figures 3-C and 3-E). Tie wrap harness in three (3) places. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4407 FIGURE 3D - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4408 FIGURE 3-F - BODY WIRING Vehicles With 22 Gallon Tank Route harness, PN 4362293, along right frame rail following brake lines (Figures 3-D and 3-E). Tie wrap in two (2) places. NOTE: HARNESS MUST BE ABOVE SHOCK STRUT WITH EITHER 36 OR 22 GALLON TANK. 2. At crossmember, route harness to the left rail following existing brake lines and tie wrap in two (2) places. At left rail, route harness forward through access holes following existing brake lines. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4409 FIGURE 3-F - BODY WIRING NOTE: HARNESS SHOULD BE TIGHT IN THIS AREA THE WRAP IN FOUR (4) PLACES (FIGURE 3-E). 3. At engine compartment, route harness through existing speedometer cable clips to bulkhead connector. If excess wiring exists; loop, tie wrap (2), and install into existing clip (Figure 3-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4410 FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 4. Plug bare terminal of harness, PN 4362293, into cavity #13 of the bulkhead connector (Figure 1-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4411 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4412 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4413 FIGURE 9 - ELECTRIC FUEL PUMP WIRING DIAGRAMW/AUX A/C & HEATER-W/O POWER WINDOWS 5. For all vehicles except those which require a 78 amp alternator package: Reinstall instrument panel side, then engine compartment side of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURES 7, 8, OR 9 FOR OVERALL WIRING DIAGRAMS. E.Engine Compartment Fuel Reservoir/Filter Lnstallation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4414 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER 1. Using template, PN 4418011, mark and drill (from engine side of passenger side chassis rail) two (2) holes .290" diameter (L size drill) as shown in Figure 4-A. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4415 FIGURE 4B - Mounting Fuel Resevoir/Filter 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. NOTE: RUBBER SPLASH SHIELD MAY HAVE TO BE CUT OUT AROUND FUEL RESERVOIR. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube, PN 4306968 (Figure 4-B). 4. Install return hose assembly, PN 4418006, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end (Figure 4-B). 5. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 42O3576. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4416 FIGURE 4B - Mounting Fuel Resevoir/Filter 6. Install one 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the fuel pump outlet tube to the reservoir/filter inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). 7. Install the other 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 8. Tighten all hose clamps to 10 inch pounds. FIGURE 10 9. Type Authorized Modification Label, PN 4275086, as shown in Figure 10 and attach near VECI label. 10. For all models except 1981-1984 equipped with Carter Thermoquad 4BBL carburetor or dual air conditioning units without electrically Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4417 heated rear window defroster. Reconnect battery. Start the engine, and inspect the entire system for fuel leaks and proper wire and hose routing. 11. Reinstall engine cover. F.1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (Pn 4397 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6O22254, (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT, AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6O22254. THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4418 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference with nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose-to-regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. For all models except those equipped with dual air conditioning units, without electrically heated rear window defroster and with 60 amp alternator: 6. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 7. Reinstall engine cover. G.Vehicles Equipped With Dual Air Conditioning Units, Without Electrically Heated Rear Defroster, and With 60 Amp Alternator. I Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4419 HEADLAMP AND DASH WIRING ASSEMBLY 1. Disconnect the battery positive lead (single in-line connection) from the headlamp and dash wiring assembly (Figure 6-A). FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 2. Remove the following wires from the engine compartment side of the bulkhead connector (Figure 6-B). a. Red wire from cavity #39 (ammeter). b. Black wire from cavity #33 (ammeter). Cut off the terminals and wrap tape around each end of both wires to insure that shorting cannot occur. Then tape the wrapped wires back against the main harness. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4420 FIGURE 6-C - 78 AMP ALTERNATOR WIRING 3. Remove the alternator output wire (heavy gauge) from the 60 amp alternator (Figure 6-C). Cut the wire off leaving approximately three (3) inches of wire extending out of the main harness. Tape the end of the lead thoroughly. Then fold and tape the lead back against the main harness to prevent shorting. 4. Remove 60 amp alternator assembly and install 78 amp alternator assembly, PN 4111204, per the service manual alternator replacement procedure. HEADLAMP AND DASH WIRING ASSEMBLY Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4421 FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 5. Beginning at the bulkhead, route and connect the wiring assembly, PN 4362343, as shown in Figure 6-A. Use the existing clip for main harness and tie wrap with three (3) tie wraps, PN 6015756. Insert the two bare terminals from alternator overlay wiring harness, PN 4362343, as shown in Figure 6-B as follows: NOTE: THE 4362343 ALTERNATOR OVERLAY HARNESS WAS MANUFACTURED WITH THE RED AND BLACK WIRES REVERSED. THEREFORE, IT WILL BE NECESSARY TO INSTALL THE BLACK WIRE (LABELED RED) INTO CAVITY #39 (RED WIRE PREVIOUSLY REMOVED), AND THE RED WIRE (LABELED BLACK) INTO CAVITY #33 (BLACK WIRE PREVIOUSLY REMOVED). FAILURE TO REVERSE THESE TWO WIRES WILL RESULT IN THE AMMETER SHOWING THE OPPOSITE CHARGE INDICATION. a. Red wire into cavity #33 (ammeter) - (labeled as black wire). b. Black wire into cavity #39 (ammeter) - (labeled as red wire). 6. Install wiring assembly, PN 4362343, alternator output terminal to new 78 amp alternator. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4422 FIGURE 6A1 7. Connect the battery positive lead and the headlamp and dash wiring assembly lead to those of the alternator overlay wiring assembly, PN 4362343, as shown in circled view of Figure 6-A. 8. Reinstall instrument panel half, then engine compartment half of bulkhead connector and torque to 40 inch pounds. 9. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 10. Reinstall engine cover. POLICY: Reimbursable within the provisions of the warranty and repair manual. TIME ALLOWANCE: Labor Operation No. 14-70-17-94 - All 2.5 Hrs. Optional Equipment: 14-70-17-60 - Carter Thermoquad Carburetor 0.5 Hrs. 14-70-17-61 - With Auxiliary A/C - Without Elec. 0.7 Hrs. Rear Window Defroster 14-70-17-62 - Without Auxiliary A/C 0.3 Hrs. 14-70-17-63 - With Auxiliary A/C - Without 0.4 Hrs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4423 Power Windows FAILURE CODE: AM - Authorized Modification Part List VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 22 GALLON FUEL TANK PACKAGE PART NO. 4397611 QTY PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075432 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Seal - Fuel Tank Gauge 3404451 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 36 GALLON FUEL TANK PACKAGE PART NO. 4397612 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075436 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Gasket - Fuel Tank Sending Unit 4115209 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4424 *It may be necessary to order clamp separately on early released packages. PARTS LIST FUEL PRESSURE REGULATOR PACKAGE FOR 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO.4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 PARTS LIST 78 AMP ALTERNATOR PACKAGE FOR 1981-1985 B MODEL TRUCKS WITH 5.2L OR 5.9L ENGINES PACKAGE PART NO. 4397615 QTY. PART NAME PART NO. 1 78 AMP Alternator Assembly - Complete 4111204 1 Alternator Overlay Wiring Harness 4362343 4 Tie Wrap 6015756 1 Gasket - Bulkhead Connector 4055399 FIGURE 4B - Mounting Fuel Resevoir/Filter 1. Fuel Filter/ Reservoir - 4418012 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4425 2. Screw - Self Tapping - 6022777 (2 Req.) 3. Tube Assy - Fuel Pump to Reservoir - 4306968 4. Return Hose & Sleeve Assy - 4418006 5. Hose Clamps - 6500650 (2 Req.) - 1/4" 6. Hose-Fuel Pump Outlet to Reservoir Inlet - 4203576 7. Hose-Reservoir Outlet to Carburetor or Regulator Fuel Tube - 4203576 8. Hose Clamps - 6500651 (4 Req.) - 5/16" Included but not shown: 2 piece Convolute Tubing - 4279993 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1 SCREW & WASHER - 6022254 2 REGULATOR BRACKET - 4418010 3 REGULATOR - 4418OD9 4 TUBE - REGULATOR TO CARB - 4418008 5 TUBE - RESERVOIR HOSE TO REGULATOR - 4418014 6 SCREW (2 EA.) - REGULATOR TO BRACKET - 6033066 7 CLAMP (5116) - 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4431 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4432 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4433 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4434 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4435 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4436 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4437 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4438 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4439 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4440 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4441 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4442 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4443 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4444 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4445 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock Technical Service Bulletin # 181985A Date: 851201 Fuel System - Vapor Lock Models 1981-1985 Van & Wagon Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 20, 1985 No. 18-19-85 REVISION A P-4782-C This bulletin supersedes Technical Service Bulletin #18-19-85 which should be removed from your files. The model application has been expanded to include 1981 and 1982 model years. SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING TWO PART NUMBERS: Vapor Lock Package With 22 Gallon Fuel Tank PN 4397611 Vapor Lock Package With 36 Gallon Fuel Tank PN 4397612 ADDITIONAL PARTS INFORMATION ON NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 All vehicles equipped with dual air conditioning, without electrically heated rear window defroster, and with 60 amp alternator must order the following package in addition to the vapor lock package. If vehicle is equipped with a 114 amp alternator, do not order this package or make any changes to the charging system. 1 78 AMP Alternator Package PN 4397615 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4450 Refer to parts list for contents of each package. Must be ordered separately: 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. REPAIR PROCEDURE A.Engine Compartment Harness Pn 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1A - ENGINE COMPARTMENT WIRING 3. Remove engine cover. Install the bare eyelet terminal of overlay harness, PN 4362295, to the negative terminal of the ignition coil as shown in Figure 1-A. FIGURE 1B - ENGINE COMPARTMENT WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4451 4. Route and secure the engine overlay harness, PN 4362295, along the existing main engine wiring harness using the existing wiring clips and two tie wraps, PN 6015756 (Figure 1-B). FIGURE 1C - ENGINE COMPARTMENT WIRING 5. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness to the bulkhead connector using the existing wiring clips and three tie wraps, PN 6015756 (Figure 1-C). Loop and tape any excess wire of the engine overlay harness. FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 6. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar multi-purpose grease PN 4318063, and snap into cavity #14 of the engine side of the bulkhead connector (Figure 1-D). B.Instrument Panel Harnesses Pn 4362289, All Models Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4452 FIGURE 2A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) 1. Remove instrument panel left lower trim panel. 2. Insert two bare terminals from instrument panel overlay harness, PN 4362289, into the instrument panel side of the bulkhead connector (Figure 2-A). a. Gray with black tracer wire into cavity #14. b. Dark green wire into cavity #13. INSTRUMENT PANEL WIRING 3. Secure bare eyelet ground terminal (white with black tracer wire) from instrument panel overlay harness, PN 4362289, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). NOTE: CERTAIN VEHICLES ARE ALREADY EQUIPPED WITH THE GROUND SCREW. IF SO, DISCARD THE SUPPLIED SCREW. FIGURE 2C - INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4453 FIGURE 2D - INSTRUMENT PANEL WIRING 4. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-C). Install the extracted terminal (orange wire) into the natural colored 1-way connector supplied with instrument panel overlay harness, PN 4362289. Install the bare terminal (orange wire) from the instrument panel overlay harness, PN 4362289, into the vacated cavity in the ignition switch connector. Reconnect the natural colored 1-way connectors supplied with the instrument panel overlay harness, PN 4362289, and reconnect the ignition switch connectors (Figure 2-C and 2-D). FIGURE 2E - TYPICAL CONTROL MODULE MOUNTING 5. Connect the control (auto shut-down) module, PN 5226640, to the natural colored 8-way connector from instrument panel overlay harness, PN 4362289. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4454 FIGURE 2D - INSTRUMENT PANEL WIRING FIGURE 2F - INSTRUMENT PANEL WIRING 6. Route the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289, to the back of the brake bracket for mating in a later step (Figures 2-B, 2-D, and 2-F). Secure instrument panel overlay harness, PN 4362289, using tie wrap, PN 6015756, to keep it clear of any possible interferences. Only one of the following installation procedures (Step 7) will be used. Take notice of which one applies to the vehicle being repaired. 7. Without Auxiliary Air Conditioning and/or Heater - Jumper Harness PN 4362291 a. Remove instrument panel hood and bezel assembly and remove radio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4455 FIGURE 2D - INSTRUMENT PANEL WIRING b. Route instrument panel jumper harness, PN 4362291, from the back of the brake bracket to the existing 3-way red molded connector. Secure by using existing wiring clips (Figure 2-D). c. Insert the bare bullet terminal (black with white tracer wire) from instrument panel jumper harness, PN 4362291, into the existing 3-way red molded connector from the main instrument panel wiring harness (Figure 2-D). d. Mate the orange colored 1-way connector from instrument panel jumper harness, PN 4362291, to the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). e. Reinstall instrument panel hood and bezel assembly and install radio. FIGURE 2F - INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater and Power Windows - Jumper Harness PN 4362292 a. Disconnect from each other, the two existing brown colored 1-way connectors located near the left instrument panel vent (Figure 2-F). Reconnect these two brown colored 1-way connectors to the two brown colored 1-way connectors from instrument panel jumper harness, PN 4362292 (Figure 2-F). b. Mate the orange colored 1-way connector from the instrument panel jumper harness, PN 4362292, to the orange colored 1-way connector from instrument panel overlay harness, PN 4362289 (Figure 2-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4456 INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater Without Power Windows - Relay Harness PN 4362290 a. Remove instrument panel hood and bezel assembly. Remove radio. b. Install the ignition switch protection relay, PN 4162597, to the back of the brake bracket (mounting location shown in Figure 2-B) and attach instrument panel relay harness, PN 4362290, to relay. c. Secure bare eyelet ground terminal (white wire) from instrument panel relay harness, PN 4362290, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING d. Route the dark blue wire from the instrument panel relay harness, PN 4362290 to the existing 3-way red molded connector using existing wiring clips. Insert bullet terminal (dark blue wire) into red molded connector (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4457 INSTRUMENT PANEL WIRING e. Insert bare bullet terminal (red wire) from instrument panel relay harness, PN 4362290, into the existing 3-way yellow molded connector from the main instrument panel wiring harness (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING f. Mate the orange colored 1-way connector from instrument panel relay harness, PN 4362290, to the colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). g. Install the instrument panel left lower trim panel, instrument panel hood, bezel assembly and radio. C.In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Feed red and yellow molds of body wiring harness, PN 4362293, through slot in the crossmember. Remove existing screw for gauge unit ground. Install eyelet terminal of harness, PN 4362293 (and ground eyelet terminal of 36 gallon tank gauge/pump unit) and torque ground screw to 36 inch pounds. CAUTION: GROUND SCREW MUST BE TIGHTENED SECURELY TO OPERATE ELECTRIC PUMP AND GAUGE UNIT. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4458 FIGURE 3A - BODY WIRING FIGURE 3B - BODY WIRING Install red mold of body harness, PN 4362293, onto red stud of gauge/pump unit. Install yellow mold of harness, PN 4362293, onto black stud of gauge/pump unit (figure 3-a or 3-b). Install molded blade terminal of harness, PN 4362293, onto blade terminal of 22 gallon gauge unit only. NOTE: PREVIOUS GAUGE UNIT GROUND WILL NOT BE USED ON 22 GALLON GAUGE/PUMP UNIT. ON 36 GALLON GAUGE PUMP UNIT, THE GROUND WIRE ON HARNESS PN 4362293 WILL NOT BE USED. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. Set aside the rest of harness, PN 4362293, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. D.Body Wiring Harness Pn 4362293 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4459 FIGURE 3C - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4460 FIGURE 3-F - BODY WIRING 1. Vehicles With 36 Gallon Tank Route harness, PN 4362293, to the right (passenger) side of vehicle along the fuel line tubes and tie wrap (1). At right frame rail, route harness forward to next crossmember (Figures 3-C and 3-E). Tie wrap harness in three (3) places. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4461 FIGURE 3D - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4462 FIGURE 3-F - BODY WIRING Vehicles With 22 Gallon Tank Route harness, PN 4362293, along right frame rail following brake lines (Figures 3-D and 3-E). Tie wrap in two (2) places. NOTE: HARNESS MUST BE ABOVE SHOCK STRUT WITH EITHER 36 OR 22 GALLON TANK. 2. At crossmember, route harness to the left rail following existing brake lines and tie wrap in two (2) places. At left rail, route harness forward through access holes following existing brake lines. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4463 FIGURE 3-F - BODY WIRING NOTE: HARNESS SHOULD BE TIGHT IN THIS AREA THE WRAP IN FOUR (4) PLACES (FIGURE 3-E). 3. At engine compartment, route harness through existing speedometer cable clips to bulkhead connector. If excess wiring exists; loop, tie wrap (2), and install into existing clip (Figure 3-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4464 FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 4. Plug bare terminal of harness, PN 4362293, into cavity #13 of the bulkhead connector (Figure 1-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4465 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4466 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4467 FIGURE 9 - ELECTRIC FUEL PUMP WIRING DIAGRAMW/AUX A/C & HEATER-W/O POWER WINDOWS 5. For all vehicles except those which require a 78 amp alternator package: Reinstall instrument panel side, then engine compartment side of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURES 7, 8, OR 9 FOR OVERALL WIRING DIAGRAMS. E.Engine Compartment Fuel Reservoir/Filter Lnstallation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4468 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER 1. Using template, PN 4418011, mark and drill (from engine side of passenger side chassis rail) two (2) holes .290" diameter (L size drill) as shown in Figure 4-A. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4469 FIGURE 4B - Mounting Fuel Resevoir/Filter 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. NOTE: RUBBER SPLASH SHIELD MAY HAVE TO BE CUT OUT AROUND FUEL RESERVOIR. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube, PN 4306968 (Figure 4-B). 4. Install return hose assembly, PN 4418006, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end (Figure 4-B). 5. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 42O3576. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4470 FIGURE 4B - Mounting Fuel Resevoir/Filter 6. Install one 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the fuel pump outlet tube to the reservoir/filter inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). 7. Install the other 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 8. Tighten all hose clamps to 10 inch pounds. FIGURE 10 9. Type Authorized Modification Label, PN 4275086, as shown in Figure 10 and attach near VECI label. 10. For all models except 1981-1984 equipped with Carter Thermoquad 4BBL carburetor or dual air conditioning units without electrically Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4471 heated rear window defroster. Reconnect battery. Start the engine, and inspect the entire system for fuel leaks and proper wire and hose routing. 11. Reinstall engine cover. F.1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (Pn 4397 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6O22254, (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT, AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6O22254. THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4472 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference with nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose-to-regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. For all models except those equipped with dual air conditioning units, without electrically heated rear window defroster and with 60 amp alternator: 6. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 7. Reinstall engine cover. G.Vehicles Equipped With Dual Air Conditioning Units, Without Electrically Heated Rear Defroster, and With 60 Amp Alternator. I Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4473 HEADLAMP AND DASH WIRING ASSEMBLY 1. Disconnect the battery positive lead (single in-line connection) from the headlamp and dash wiring assembly (Figure 6-A). FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 2. Remove the following wires from the engine compartment side of the bulkhead connector (Figure 6-B). a. Red wire from cavity #39 (ammeter). b. Black wire from cavity #33 (ammeter). Cut off the terminals and wrap tape around each end of both wires to insure that shorting cannot occur. Then tape the wrapped wires back against the main harness. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4474 FIGURE 6-C - 78 AMP ALTERNATOR WIRING 3. Remove the alternator output wire (heavy gauge) from the 60 amp alternator (Figure 6-C). Cut the wire off leaving approximately three (3) inches of wire extending out of the main harness. Tape the end of the lead thoroughly. Then fold and tape the lead back against the main harness to prevent shorting. 4. Remove 60 amp alternator assembly and install 78 amp alternator assembly, PN 4111204, per the service manual alternator replacement procedure. HEADLAMP AND DASH WIRING ASSEMBLY Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4475 FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 5. Beginning at the bulkhead, route and connect the wiring assembly, PN 4362343, as shown in Figure 6-A. Use the existing clip for main harness and tie wrap with three (3) tie wraps, PN 6015756. Insert the two bare terminals from alternator overlay wiring harness, PN 4362343, as shown in Figure 6-B as follows: NOTE: THE 4362343 ALTERNATOR OVERLAY HARNESS WAS MANUFACTURED WITH THE RED AND BLACK WIRES REVERSED. THEREFORE, IT WILL BE NECESSARY TO INSTALL THE BLACK WIRE (LABELED RED) INTO CAVITY #39 (RED WIRE PREVIOUSLY REMOVED), AND THE RED WIRE (LABELED BLACK) INTO CAVITY #33 (BLACK WIRE PREVIOUSLY REMOVED). FAILURE TO REVERSE THESE TWO WIRES WILL RESULT IN THE AMMETER SHOWING THE OPPOSITE CHARGE INDICATION. a. Red wire into cavity #33 (ammeter) - (labeled as black wire). b. Black wire into cavity #39 (ammeter) - (labeled as red wire). 6. Install wiring assembly, PN 4362343, alternator output terminal to new 78 amp alternator. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4476 FIGURE 6A1 7. Connect the battery positive lead and the headlamp and dash wiring assembly lead to those of the alternator overlay wiring assembly, PN 4362343, as shown in circled view of Figure 6-A. 8. Reinstall instrument panel half, then engine compartment half of bulkhead connector and torque to 40 inch pounds. 9. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 10. Reinstall engine cover. POLICY: Reimbursable within the provisions of the warranty and repair manual. TIME ALLOWANCE: Labor Operation No. 14-70-17-94 - All 2.5 Hrs. Optional Equipment: 14-70-17-60 - Carter Thermoquad Carburetor 0.5 Hrs. 14-70-17-61 - With Auxiliary A/C - Without Elec. 0.7 Hrs. Rear Window Defroster 14-70-17-62 - Without Auxiliary A/C 0.3 Hrs. 14-70-17-63 - With Auxiliary A/C - Without 0.4 Hrs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4477 Power Windows FAILURE CODE: AM - Authorized Modification Part List VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 22 GALLON FUEL TANK PACKAGE PART NO. 4397611 QTY PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075432 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Seal - Fuel Tank Gauge 3404451 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 36 GALLON FUEL TANK PACKAGE PART NO. 4397612 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075436 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Gasket - Fuel Tank Sending Unit 4115209 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4478 *It may be necessary to order clamp separately on early released packages. PARTS LIST FUEL PRESSURE REGULATOR PACKAGE FOR 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO.4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 PARTS LIST 78 AMP ALTERNATOR PACKAGE FOR 1981-1985 B MODEL TRUCKS WITH 5.2L OR 5.9L ENGINES PACKAGE PART NO. 4397615 QTY. PART NAME PART NO. 1 78 AMP Alternator Assembly - Complete 4111204 1 Alternator Overlay Wiring Harness 4362343 4 Tie Wrap 6015756 1 Gasket - Bulkhead Connector 4055399 FIGURE 4B - Mounting Fuel Resevoir/Filter 1. Fuel Filter/ Reservoir - 4418012 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4479 2. Screw - Self Tapping - 6022777 (2 Req.) 3. Tube Assy - Fuel Pump to Reservoir - 4306968 4. Return Hose & Sleeve Assy - 4418006 5. Hose Clamps - 6500650 (2 Req.) - 1/4" 6. Hose-Fuel Pump Outlet to Reservoir Inlet - 4203576 7. Hose-Reservoir Outlet to Carburetor or Regulator Fuel Tube - 4203576 8. Hose Clamps - 6500651 (4 Req.) - 5/16" Included but not shown: 2 piece Convolute Tubing - 4279993 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1 SCREW & WASHER - 6022254 2 REGULATOR BRACKET - 4418010 3 REGULATOR - 4418OD9 4 TUBE - REGULATOR TO CARB - 4418008 5 TUBE - RESERVOIR HOSE TO REGULATOR - 4418014 6 SCREW (2 EA.) - REGULATOR TO BRACKET - 6033066 7 CLAMP (5116) - 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 4482 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 4483 Fuel Gauge Sender: Electrical Diagrams Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 4484 Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 4485 Fig. 15 Fuel Gauge & Seatbelt Warning System Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Page 4486 Fuel Gauge Sender: Testing and Inspection A hinged float arm in the fuel tank contacts a variable resistor in the gauge sending unit. The varying resistance in the fuel gauge circuit registers on the instrument panel gauge. Resistance in the circuit is lowest when the fuel tank is full and float arm is raised. The resulting high current flow causes the instrument panel gauge to indicate Full. TROUBLESHOOTING 1. Disconnect electrical connector from fuel tank sending unit and attach connector to a known good sending unit. 2. Connect a jumper wire between sending unit fuel pickup tube and a good ground. 3. Secure sending unit float arm in the empty stop position and turn ignition On. Within two minutes, the gauge should read Empty, plus one pointer width or minus two pointer widths. 4. Move float arm and secure in the full stop position. Within two minutes, the gauge should read Full, plus two pointer widths, or minus one pointer width. 5. If fuel gauge does not operate as specified, check the following: a. Wiring and electrical connections between sending unit and connector. b. Wiring and electrical connections between connector and printed circuit board terminals. c. Circuit continuity between printed circuit board terminals and gauge terminals. d. Voltage limiter performance. 6. If fuel gauge operates as specified with known good sending unit, check fuel tank and original sending unit as follows: a. Remove sending unit from fuel tank. b. Connect sending unit wire and jumper wire as previously described. c. If fuel gauge now operates as specified, check sending unit for damage, obstructions or improper installation and correct as necessary. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Map Lamp > Component Information > Technical Service Bulletins > Customer Interest for Map Lamp: > 080887 > Mar > 87 > Map Lamp - Mounting Tab Breakage Map Lamp: Customer Interest Map Lamp - Mounting Tab Breakage Models 1982-1987 Domestic "D" & "W" Model Trucks & Sport Utility Vehicles Subject Map Lamp Tab Breakage Index ELECTRICAL Date March 2, 1987 No. 08-08-87 (C8-08) P-627 SYMPTOM/CONDITION Broken map lamp mounting tabs for the under dash mounted map lamp. PARTS REQUIRED Lamp Mounting Bracket Repair Package PN 4439009 REPAIR PROCEDURE This repair involves the installation of a map lamp retaining bracket. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Map Lamp > Component Information > Technical Service Bulletins > Customer Interest for Map Lamp: > 080887 > Mar > 87 > Map Lamp - Mounting Tab Breakage > Page 4497 FIGURE 1 Remove the instrument bezel in accordance with service manual procedures. Locate the repair bracket PN 4439009, over the broken lamp mounting tabs on the instrument panel, and below the existing mounting tabs for the instrument panel bezel.. The repair bracket should be positioned so that it will be retained by the instrument panel bezel retaining screws (Figure 1). Carefully reinstall the instrument panel bezel, making sure the replacement bracket does not come out of position. Secure the bezel and bracket with the bezel mounting screws. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 23-11-16-90 . . . . . . 0.4 Hrs. FAILURE CODE: 11 - Broken or Cracked Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Map Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Map Lamp: > 080887 > Mar > 87 > Map Lamp - Mounting Tab Breakage Map Lamp: All Technical Service Bulletins Map Lamp - Mounting Tab Breakage Models 1982-1987 Domestic "D" & "W" Model Trucks & Sport Utility Vehicles Subject Map Lamp Tab Breakage Index ELECTRICAL Date March 2, 1987 No. 08-08-87 (C8-08) P-627 SYMPTOM/CONDITION Broken map lamp mounting tabs for the under dash mounted map lamp. PARTS REQUIRED Lamp Mounting Bracket Repair Package PN 4439009 REPAIR PROCEDURE This repair involves the installation of a map lamp retaining bracket. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Map Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Map Lamp: > 080887 > Mar > 87 > Map Lamp - Mounting Tab Breakage > Page 4503 FIGURE 1 Remove the instrument bezel in accordance with service manual procedures. Locate the repair bracket PN 4439009, over the broken lamp mounting tabs on the instrument panel, and below the existing mounting tabs for the instrument panel bezel.. The repair bracket should be positioned so that it will be retained by the instrument panel bezel retaining screws (Figure 1). Carefully reinstall the instrument panel bezel, making sure the replacement bracket does not come out of position. Secure the bezel and bracket with the bezel mounting screws. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 23-11-16-90 . . . . . . 0.4 Hrs. FAILURE CODE: 11 - Broken or Cracked Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions Instrument Panel Circuit Board: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 4508 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 4509 Fig. 3 Instrument Panel Printed Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4514 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4515 Fig. 8 Cargo, Dome & Map Lamps Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair This reminder uses mileage impulse counting contacts to calculate maintenance intervals. The module is located to the right of the steering column. After necessary emission maintenance has been performed, reset module as follows: 1. Slide module from bracket. 2. Insert a small screwdriver into small hole on module case and close switch. 3. Remove module battery cover and install a replacement 9 volt battery. 4. Position module on mounting bracket. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Testing and Inspection Oil Level Warning Indicator: Testing and Inspection Remote Recreational Vehicle Sensor Package Fig. 3 Recreational vehicle sensor package instrument cluster. 1980 Fig. 4 Recreational vehicle sensor package instrument cluster. 1981-82 The recreational vehicle sensor package consists of a separate instrument cluster which allows the driver to monitor the following conditions: engine oil level, engine coolant level, transmission fluid level and transmission fluid temperature. TROUBLESHOOTING VOLTAGE LIMITER TEST 1. Connect voltmeter between temperature sending unit (locating in fitting in bottom radiator tank) and a suitable ground. Do not disconnect electrical connector from sending unit. 2. Turn ignition switch to On position and observe voltmeter. 3. If voltmeter needle fluctuates, the voltage limiter is operating properly. 4. If voltmeter does not fluctuate, replace voltage limiter. The voltage limiter is located on the sensor panel. To gain access to the limiter, remove panel and unsnap the back cover. TEMPERATURE GAUGE TEST 1. Disconnect electrical connector from temperature sending unit in lower radiator tank. 2. Connect tester No. C-3826 or equivalent between temperature sending unit and a suitable ground. 3. Move tester pointer to "C" position, then turn ignition switch On and observe temperature gauge. Temperature gauge should read within 1/8 inch of "C". 4. Move tester pointer to "M" position. Temperature gauge should now advance to normal range left of 1/2 position on dial. 5. Move tester pointer to "H" position. Temperature gauge should now advance to "H" position on dial. 6. If temperature gauge responds to tests described in steps 3, 4 and 5, but does not operate when sending unit electrical connector is attached, the sending unit is defective and should be replaced. 7. If temperature gauge does not respond to tests described in steps 3, 4 and 5, check for loose connections, broken wire, open printed circuit or faulty gauge. OIL LEVEL PUSH BUTTON SWITCH 1. Inspect switch for poor solder connections and repair or replace as necessary. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Testing and Inspection > Page 4522 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the switch should be replaced. To replace switch, remove circuit board and push switch toward back of sensor housing. PRINTED CIRCUIT BOARD 1. Inspect conductors for cracks or damaged circuits. 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the sensor panel assembly should be replaced. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation CONSTANT VOLTAGE REGULATOR (CVR) TYPE This oil pressure indicating system incorporates an instrument voltage regulator, electrical oil pressure gauge and a sending unit which are connected in series. The sending unit consists of a diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm actuated the contact on the variable resistor, in turn controlling current flow to the gauge. When oil pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge, in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor is lowered, permitting an increased current flow to the gauge, resulting in an increased gauge reading. TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions included with the tester. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Description and Operation > Page 4526 Oil Pressure Gauge: Testing and Inspection CONSTANT VOLTAGE REGULATOR (CVR) TYPE This oil pressure indicating system incorporates an instrument voltage regulator, electrical oil pressure gauge and a sending unit which are connected in series. The sending unit consists of a diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm actuated the contact on the variable resistor, in turn controlling current flow to the gauge. When oil pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge, in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor is lowered, permitting an increased current flow to the gauge, resulting in an increased gauge reading. TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions included with the tester. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Engine Mounted Switches & Sensors. Top Of Engine Applicable to: V8 Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation Many trucks utilize a warning light on the instrument panel in place of the conventional dash indicating gauge to warn the driver when the oil pressure is dangerously low. The warning light is wired in series with the ignition switch and the engine unit, which is an oil pressure switch. The oil pressure switch contains a diaphragm and a set of contacts. When the ignition switch is turned on, the warning light circuit is energized and the circuit is completed through the closed contacts in the pressure switch. When the engine is started, build-up of oil pressure compresses the diaphragm, opening the contacts, thereby breaking the circuit and putting out the light. TROUBLESHOOTING The oil pressure warning light should go on when the ignition is turned on. If it does not light, disconnect the wire from the engine unit and ground the wire to the frame or cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight and properly grounded, it should be removed and a new one installed. (The presence of sealing compound on the threads of the engine unit will cause a poor ground). If the warning light remains lit when it normally should be out, replace the engine unit before proceeding further to determine the cause for a low pressure indication. The warning light will sometimes light up or flicker when the engine is idling, even though the oil pressure is adequate. However, the light should go out when the engine speed is increased. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Page 4533 Oil Pressure Warning Lamp/Indicator: Testing and Inspection Many trucks utilize a warning light on the instrument panel in place of the conventional dash indicating gauge to warn the driver when the oil pressure is dangerously low. The warning light is wired in series with the ignition switch and the engine unit, which is an oil pressure switch. The oil pressure switch contains a diaphragm and a set of contacts. When the ignition switch is turned on, the warning light circuit is energized and the circuit is completed through the closed contacts in the pressure switch. When the engine is started, build-up of oil pressure compresses the diaphragm, opening the contacts, thereby breaking the circuit and putting out the light. TROUBLESHOOTING The oil pressure warning light should go on when the ignition is turned on. If it does not light, disconnect the wire from the engine unit and ground the wire to the frame or cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight and properly grounded, it should be removed and a new one installed. (The presence of sealing compound on the threads of the engine unit will cause a poor ground). If the warning light remains lit when it normally should be out, replace the engine unit before proceeding further to determine the cause for a low pressure indication. The warning light will sometimes light up or flicker when the engine is idling, even though the oil pressure is adequate. However, the light should go out when the engine speed is increased. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Parking Brake Warning Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4538 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4539 Parking Brake Warning Switch: Electrical Diagrams Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4540 Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4546 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4547 Fig. 8 Cargo, Dome & Map Lamps Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4556 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4557 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4558 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4559 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4560 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4561 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4562 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4563 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4564 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4565 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4566 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4567 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4568 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4569 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4570 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock Technical Service Bulletin # 181985A Date: 851201 Fuel System - Vapor Lock Models 1981-1985 Van & Wagon Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 20, 1985 No. 18-19-85 REVISION A P-4782-C This bulletin supersedes Technical Service Bulletin #18-19-85 which should be removed from your files. The model application has been expanded to include 1981 and 1982 model years. SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING TWO PART NUMBERS: Vapor Lock Package With 22 Gallon Fuel Tank PN 4397611 Vapor Lock Package With 36 Gallon Fuel Tank PN 4397612 ADDITIONAL PARTS INFORMATION ON NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 All vehicles equipped with dual air conditioning, without electrically heated rear window defroster, and with 60 amp alternator must order the following package in addition to the vapor lock package. If vehicle is equipped with a 114 amp alternator, do not order this package or make any changes to the charging system. 1 78 AMP Alternator Package PN 4397615 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4575 Refer to parts list for contents of each package. Must be ordered separately: 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. REPAIR PROCEDURE A.Engine Compartment Harness Pn 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1A - ENGINE COMPARTMENT WIRING 3. Remove engine cover. Install the bare eyelet terminal of overlay harness, PN 4362295, to the negative terminal of the ignition coil as shown in Figure 1-A. FIGURE 1B - ENGINE COMPARTMENT WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4576 4. Route and secure the engine overlay harness, PN 4362295, along the existing main engine wiring harness using the existing wiring clips and two tie wraps, PN 6015756 (Figure 1-B). FIGURE 1C - ENGINE COMPARTMENT WIRING 5. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness to the bulkhead connector using the existing wiring clips and three tie wraps, PN 6015756 (Figure 1-C). Loop and tape any excess wire of the engine overlay harness. FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 6. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar multi-purpose grease PN 4318063, and snap into cavity #14 of the engine side of the bulkhead connector (Figure 1-D). B.Instrument Panel Harnesses Pn 4362289, All Models Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4577 FIGURE 2A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) 1. Remove instrument panel left lower trim panel. 2. Insert two bare terminals from instrument panel overlay harness, PN 4362289, into the instrument panel side of the bulkhead connector (Figure 2-A). a. Gray with black tracer wire into cavity #14. b. Dark green wire into cavity #13. INSTRUMENT PANEL WIRING 3. Secure bare eyelet ground terminal (white with black tracer wire) from instrument panel overlay harness, PN 4362289, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). NOTE: CERTAIN VEHICLES ARE ALREADY EQUIPPED WITH THE GROUND SCREW. IF SO, DISCARD THE SUPPLIED SCREW. FIGURE 2C - INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4578 FIGURE 2D - INSTRUMENT PANEL WIRING 4. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-C). Install the extracted terminal (orange wire) into the natural colored 1-way connector supplied with instrument panel overlay harness, PN 4362289. Install the bare terminal (orange wire) from the instrument panel overlay harness, PN 4362289, into the vacated cavity in the ignition switch connector. Reconnect the natural colored 1-way connectors supplied with the instrument panel overlay harness, PN 4362289, and reconnect the ignition switch connectors (Figure 2-C and 2-D). FIGURE 2E - TYPICAL CONTROL MODULE MOUNTING 5. Connect the control (auto shut-down) module, PN 5226640, to the natural colored 8-way connector from instrument panel overlay harness, PN 4362289. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4579 FIGURE 2D - INSTRUMENT PANEL WIRING FIGURE 2F - INSTRUMENT PANEL WIRING 6. Route the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289, to the back of the brake bracket for mating in a later step (Figures 2-B, 2-D, and 2-F). Secure instrument panel overlay harness, PN 4362289, using tie wrap, PN 6015756, to keep it clear of any possible interferences. Only one of the following installation procedures (Step 7) will be used. Take notice of which one applies to the vehicle being repaired. 7. Without Auxiliary Air Conditioning and/or Heater - Jumper Harness PN 4362291 a. Remove instrument panel hood and bezel assembly and remove radio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4580 FIGURE 2D - INSTRUMENT PANEL WIRING b. Route instrument panel jumper harness, PN 4362291, from the back of the brake bracket to the existing 3-way red molded connector. Secure by using existing wiring clips (Figure 2-D). c. Insert the bare bullet terminal (black with white tracer wire) from instrument panel jumper harness, PN 4362291, into the existing 3-way red molded connector from the main instrument panel wiring harness (Figure 2-D). d. Mate the orange colored 1-way connector from instrument panel jumper harness, PN 4362291, to the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). e. Reinstall instrument panel hood and bezel assembly and install radio. FIGURE 2F - INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater and Power Windows - Jumper Harness PN 4362292 a. Disconnect from each other, the two existing brown colored 1-way connectors located near the left instrument panel vent (Figure 2-F). Reconnect these two brown colored 1-way connectors to the two brown colored 1-way connectors from instrument panel jumper harness, PN 4362292 (Figure 2-F). b. Mate the orange colored 1-way connector from the instrument panel jumper harness, PN 4362292, to the orange colored 1-way connector from instrument panel overlay harness, PN 4362289 (Figure 2-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4581 INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater Without Power Windows - Relay Harness PN 4362290 a. Remove instrument panel hood and bezel assembly. Remove radio. b. Install the ignition switch protection relay, PN 4162597, to the back of the brake bracket (mounting location shown in Figure 2-B) and attach instrument panel relay harness, PN 4362290, to relay. c. Secure bare eyelet ground terminal (white wire) from instrument panel relay harness, PN 4362290, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING d. Route the dark blue wire from the instrument panel relay harness, PN 4362290 to the existing 3-way red molded connector using existing wiring clips. Insert bullet terminal (dark blue wire) into red molded connector (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4582 INSTRUMENT PANEL WIRING e. Insert bare bullet terminal (red wire) from instrument panel relay harness, PN 4362290, into the existing 3-way yellow molded connector from the main instrument panel wiring harness (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING f. Mate the orange colored 1-way connector from instrument panel relay harness, PN 4362290, to the colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). g. Install the instrument panel left lower trim panel, instrument panel hood, bezel assembly and radio. C.In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Feed red and yellow molds of body wiring harness, PN 4362293, through slot in the crossmember. Remove existing screw for gauge unit ground. Install eyelet terminal of harness, PN 4362293 (and ground eyelet terminal of 36 gallon tank gauge/pump unit) and torque ground screw to 36 inch pounds. CAUTION: GROUND SCREW MUST BE TIGHTENED SECURELY TO OPERATE ELECTRIC PUMP AND GAUGE UNIT. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4583 FIGURE 3A - BODY WIRING FIGURE 3B - BODY WIRING Install red mold of body harness, PN 4362293, onto red stud of gauge/pump unit. Install yellow mold of harness, PN 4362293, onto black stud of gauge/pump unit (figure 3-a or 3-b). Install molded blade terminal of harness, PN 4362293, onto blade terminal of 22 gallon gauge unit only. NOTE: PREVIOUS GAUGE UNIT GROUND WILL NOT BE USED ON 22 GALLON GAUGE/PUMP UNIT. ON 36 GALLON GAUGE PUMP UNIT, THE GROUND WIRE ON HARNESS PN 4362293 WILL NOT BE USED. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. Set aside the rest of harness, PN 4362293, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. D.Body Wiring Harness Pn 4362293 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4584 FIGURE 3C - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4585 FIGURE 3-F - BODY WIRING 1. Vehicles With 36 Gallon Tank Route harness, PN 4362293, to the right (passenger) side of vehicle along the fuel line tubes and tie wrap (1). At right frame rail, route harness forward to next crossmember (Figures 3-C and 3-E). Tie wrap harness in three (3) places. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4586 FIGURE 3D - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4587 FIGURE 3-F - BODY WIRING Vehicles With 22 Gallon Tank Route harness, PN 4362293, along right frame rail following brake lines (Figures 3-D and 3-E). Tie wrap in two (2) places. NOTE: HARNESS MUST BE ABOVE SHOCK STRUT WITH EITHER 36 OR 22 GALLON TANK. 2. At crossmember, route harness to the left rail following existing brake lines and tie wrap in two (2) places. At left rail, route harness forward through access holes following existing brake lines. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4588 FIGURE 3-F - BODY WIRING NOTE: HARNESS SHOULD BE TIGHT IN THIS AREA THE WRAP IN FOUR (4) PLACES (FIGURE 3-E). 3. At engine compartment, route harness through existing speedometer cable clips to bulkhead connector. If excess wiring exists; loop, tie wrap (2), and install into existing clip (Figure 3-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4589 FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 4. Plug bare terminal of harness, PN 4362293, into cavity #13 of the bulkhead connector (Figure 1-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4590 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4591 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4592 FIGURE 9 - ELECTRIC FUEL PUMP WIRING DIAGRAMW/AUX A/C & HEATER-W/O POWER WINDOWS 5. For all vehicles except those which require a 78 amp alternator package: Reinstall instrument panel side, then engine compartment side of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURES 7, 8, OR 9 FOR OVERALL WIRING DIAGRAMS. E.Engine Compartment Fuel Reservoir/Filter Lnstallation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4593 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER 1. Using template, PN 4418011, mark and drill (from engine side of passenger side chassis rail) two (2) holes .290" diameter (L size drill) as shown in Figure 4-A. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4594 FIGURE 4B - Mounting Fuel Resevoir/Filter 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. NOTE: RUBBER SPLASH SHIELD MAY HAVE TO BE CUT OUT AROUND FUEL RESERVOIR. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube, PN 4306968 (Figure 4-B). 4. Install return hose assembly, PN 4418006, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end (Figure 4-B). 5. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 42O3576. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4595 FIGURE 4B - Mounting Fuel Resevoir/Filter 6. Install one 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the fuel pump outlet tube to the reservoir/filter inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). 7. Install the other 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 8. Tighten all hose clamps to 10 inch pounds. FIGURE 10 9. Type Authorized Modification Label, PN 4275086, as shown in Figure 10 and attach near VECI label. 10. For all models except 1981-1984 equipped with Carter Thermoquad 4BBL carburetor or dual air conditioning units without electrically Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4596 heated rear window defroster. Reconnect battery. Start the engine, and inspect the entire system for fuel leaks and proper wire and hose routing. 11. Reinstall engine cover. F.1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (Pn 4397 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6O22254, (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT, AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6O22254. THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4597 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference with nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose-to-regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. For all models except those equipped with dual air conditioning units, without electrically heated rear window defroster and with 60 amp alternator: 6. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 7. Reinstall engine cover. G.Vehicles Equipped With Dual Air Conditioning Units, Without Electrically Heated Rear Defroster, and With 60 Amp Alternator. I Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4598 HEADLAMP AND DASH WIRING ASSEMBLY 1. Disconnect the battery positive lead (single in-line connection) from the headlamp and dash wiring assembly (Figure 6-A). FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 2. Remove the following wires from the engine compartment side of the bulkhead connector (Figure 6-B). a. Red wire from cavity #39 (ammeter). b. Black wire from cavity #33 (ammeter). Cut off the terminals and wrap tape around each end of both wires to insure that shorting cannot occur. Then tape the wrapped wires back against the main harness. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4599 FIGURE 6-C - 78 AMP ALTERNATOR WIRING 3. Remove the alternator output wire (heavy gauge) from the 60 amp alternator (Figure 6-C). Cut the wire off leaving approximately three (3) inches of wire extending out of the main harness. Tape the end of the lead thoroughly. Then fold and tape the lead back against the main harness to prevent shorting. 4. Remove 60 amp alternator assembly and install 78 amp alternator assembly, PN 4111204, per the service manual alternator replacement procedure. HEADLAMP AND DASH WIRING ASSEMBLY Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4600 FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 5. Beginning at the bulkhead, route and connect the wiring assembly, PN 4362343, as shown in Figure 6-A. Use the existing clip for main harness and tie wrap with three (3) tie wraps, PN 6015756. Insert the two bare terminals from alternator overlay wiring harness, PN 4362343, as shown in Figure 6-B as follows: NOTE: THE 4362343 ALTERNATOR OVERLAY HARNESS WAS MANUFACTURED WITH THE RED AND BLACK WIRES REVERSED. THEREFORE, IT WILL BE NECESSARY TO INSTALL THE BLACK WIRE (LABELED RED) INTO CAVITY #39 (RED WIRE PREVIOUSLY REMOVED), AND THE RED WIRE (LABELED BLACK) INTO CAVITY #33 (BLACK WIRE PREVIOUSLY REMOVED). FAILURE TO REVERSE THESE TWO WIRES WILL RESULT IN THE AMMETER SHOWING THE OPPOSITE CHARGE INDICATION. a. Red wire into cavity #33 (ammeter) - (labeled as black wire). b. Black wire into cavity #39 (ammeter) - (labeled as red wire). 6. Install wiring assembly, PN 4362343, alternator output terminal to new 78 amp alternator. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4601 FIGURE 6A1 7. Connect the battery positive lead and the headlamp and dash wiring assembly lead to those of the alternator overlay wiring assembly, PN 4362343, as shown in circled view of Figure 6-A. 8. Reinstall instrument panel half, then engine compartment half of bulkhead connector and torque to 40 inch pounds. 9. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 10. Reinstall engine cover. POLICY: Reimbursable within the provisions of the warranty and repair manual. TIME ALLOWANCE: Labor Operation No. 14-70-17-94 - All 2.5 Hrs. Optional Equipment: 14-70-17-60 - Carter Thermoquad Carburetor 0.5 Hrs. 14-70-17-61 - With Auxiliary A/C - Without Elec. 0.7 Hrs. Rear Window Defroster 14-70-17-62 - Without Auxiliary A/C 0.3 Hrs. 14-70-17-63 - With Auxiliary A/C - Without 0.4 Hrs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4602 Power Windows FAILURE CODE: AM - Authorized Modification Part List VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 22 GALLON FUEL TANK PACKAGE PART NO. 4397611 QTY PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075432 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Seal - Fuel Tank Gauge 3404451 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 36 GALLON FUEL TANK PACKAGE PART NO. 4397612 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075436 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Gasket - Fuel Tank Sending Unit 4115209 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4603 *It may be necessary to order clamp separately on early released packages. PARTS LIST FUEL PRESSURE REGULATOR PACKAGE FOR 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO.4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 PARTS LIST 78 AMP ALTERNATOR PACKAGE FOR 1981-1985 B MODEL TRUCKS WITH 5.2L OR 5.9L ENGINES PACKAGE PART NO. 4397615 QTY. PART NAME PART NO. 1 78 AMP Alternator Assembly - Complete 4111204 1 Alternator Overlay Wiring Harness 4362343 4 Tie Wrap 6015756 1 Gasket - Bulkhead Connector 4055399 FIGURE 4B - Mounting Fuel Resevoir/Filter 1. Fuel Filter/ Reservoir - 4418012 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4604 2. Screw - Self Tapping - 6022777 (2 Req.) 3. Tube Assy - Fuel Pump to Reservoir - 4306968 4. Return Hose & Sleeve Assy - 4418006 5. Hose Clamps - 6500650 (2 Req.) - 1/4" 6. Hose-Fuel Pump Outlet to Reservoir Inlet - 4203576 7. Hose-Reservoir Outlet to Carburetor or Regulator Fuel Tube - 4203576 8. Hose Clamps - 6500651 (4 Req.) - 5/16" Included but not shown: 2 piece Convolute Tubing - 4279993 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1 SCREW & WASHER - 6022254 2 REGULATOR BRACKET - 4418010 3 REGULATOR - 4418OD9 4 TUBE - REGULATOR TO CARB - 4418008 5 TUBE - RESERVOIR HOSE TO REGULATOR - 4418014 6 SCREW (2 EA.) - REGULATOR TO BRACKET - 6033066 7 CLAMP (5116) - 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock Technical Service Bulletin # 185386 Date: 861201 Fuel System - Engine Vapor Lock Models 1981-1985 Pick-Up Truck & Ramcharger 4 x 4 or 4 x 2 Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 8, 1986 No. 18-53-86 P-4347 This bulletin supersedes Technical Service Bulletin #18-17-85 REVISION A which should be removed from your files. This bulletin is being revised to include updated part numbers and the addition of a template to the parts kit. Symptom/Condition, Diagnosis & Parts Information SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING THREE PART NUMBERS: Vapor Lock Package With 20 Gallon Fuel Tank PN 4364384 Vapor Lock Package With 30 Gallon Fuel Tank PN 4364385 Vapor Lock Package With 35 Gallon Fuel Tank PN 4364386 ADDITIONAL PARTS INFORMATION ON THE NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 Refer to parts list for contents of each package. Must be ordered separately: Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4610 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. Repair Procedure This procedure involves installation of an electric fuel pump, control module, and fuel reservoir. A. Engine Compartment Harness PN 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1-A 3. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness from the ignition coil to the bulkhead connector, using the existing wiring clips and four tie wraps, PN 6015756. Loop and tape excess wire of the overlay harness (Figure 1-A). FIGURE 1-B 4. Install the bare eyelet terminal of the overlay harness to the negative terminal of the ignition coil as shown in Figure 1-B. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4611 FIGURE 1-C - ENGINE COMPARTMENT WIRING 5. Coat the bare blade terminal of the engine overlay harness PN 4362295 liberally with Mopar multi-purpose grease PN 4318063 and snap into cavity #11 of the engine side of the bulkhead connector (Figure 1-C). FIGURE 2-A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) B. Instrument Panel Harness PN 4362284 1. Insert two bare terminals from instrument panel overlay harness, PN 4362284, into the instrument panel side of the bulkhead connector as shown in Figure 2-A and outlined below: a. Grey with black tracer wire into cavity #11. b. Dark green wire into cavity #12. FIGURE 2-B - TERMINAL END OF IGNITION SWITCH CONN. (PART OF INSTRUMENT PANEL WIRING) Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4612 INSTRUMENT PANEL WIRING 2. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-B). Install the orange wire just removed, into the natural colored 1-way connector supplied with the instrument panel overlay harness, PN 4362284. Install the bare terminal (orange wire) from the instrument panel overlay harness into the previously vacated cavity in the ignition switch connector. Reconnect the natural colored one way connectors supplied with the instrument panel overlay harness, and reconnect the ignition switch connectors (Figures 2-B and 2-C). INSTRUMENT PANEL WIRING 3. Replace the 3-amp fuse located in cavity #11 of the fuse block with the 10-amp fuse supplied in kit (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4613 INSTRUMENT PANEL WIRING 4. Route the instrument panel overlay harness along the existing instrument panel ignition switch wiring from the bulkhead connector and behind the fuse block to the existing red mold connector and instrument panel ground terminal (Figure 2-C). Secure the instrument panel overlay harness using the existing wiring clip that retains the ignition switch wiring and one tie wrap, PN 6015756 (Figure 2-C). 5. Install the female blade terminal (white with black tracer wire) from the instrument panel overlay harness onto an instrument panel ground terminal located to the right of the steering column (Figure 2-C). 6. Insert the bare terminal (light blue wire) from the instrument panel overlay harness into the existing 3-way red molded connector, from the main instrument panel wiring harness, (Located near radio, Figure 2-C). INSTRUMENT PANEL WIRING 7. Connect the control (auto shut down) module, PN 5226640, to the supplied natural colored 8-way connector from the instrument panel overlay harness, PN 4362284. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). C. In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Install existing gauge/pump wiring: ^ Black mold connector (gauge circuit) light blue with tracer wire to black stud of gauge/pump assembly. ^ Tape back existing yellow mold connector white wire (this wire will no longer be used). ^ Install red mold connector (pump feed circuit) dark green wire of new body wiring overlay harness, PN 4362286, onto the red stud of gauge/pump assembly. ^ Install yellow mold blade connector of body overlay harness, PN 4362286, to ground blade on gauge/pump assembly. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. ^ Set aside the rest of harness, PN 4362286, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4614 FIGURE 3-A Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4615 FIGURE 3-B - BODY WIRING HARNESS D. Body Wiring Harness PN 4362286 1. Route the single wire with eyelet terminal of body wiring harness, PN 4362286, to the rear of the vehicle through the existing hole in the rail (Figures 3-A and 3-B). Clip the wiring into the existing ring clips. Remove the ground screw and install both eyelet (ground) terminals into the screw and torque to 95 inch pounds. Take up excess ground wire and tie wrap as shown in Figure 3-A. 2. Route the dark green wire of harness, PN 4362286 (in-loom), to the front of the vehicle. Use the existing ring clips on the chassis rail. Tie wrap the harness as shown in Figure 3-B. NOTE: THE NUMBER OF TIE WRAPS WILL VARY WITH WHEEL BASE LENGTH. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4616 FIGURE 3-C 3. At the engine compartment, route harness, PN 4362286, through existing clips for main body harness to the bulkhead. NOTE: DUE TO VARYING WHEEL BASE LENGTHS, EXCESS WIRING MAY EXIST. WRAP EXCESS WIRING BETWEEN THE TWO CLIPS REFERENCE IN FIGURE 3-C AND TIE WRAP IN TWO (2) PLACES. 4. Plug the bare terminal of body wiring harness, PN 4362286, into cavity #12 of the engine side of the bulkhead connector. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4617 FIGURE 6 - ELECTRIC FUEL PUMP WIRING DIAGRAM 5. Reinstall instrument panel half of bulkhead connector, making sure it snaps into place. Reinstall engine compartment half of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURE 6 FOR OVERALL ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4618 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER E. Engine Compartment Fuel Reservoir/Filter Installation 1. Using template PN 4418042 for 4 x 2 models or PN 4418013 for 4 x 4 models, mark and drill (from wheel side of passenger side chassis rail Figure 4-A) two (2) holes .290" diameter (L size drill). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4619 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube (PN 4306968 for 4 x 4 or 4306967 for 4 x 2). 4. On 4 x 2 Models a. Shorten 1/4" x 10" return hose and convolute sleeve assembly, PN 4418005, to 8". Remove convolute and shorten 1". Reinstall on hose. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4620 FIGURE 4-B - FUEL RESERVOIR/FILTER INSTALLATION b. Install modified return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube (Figure 4-B), and clamp with PN 6500651 at each end. c. Shorten both 5/16" x 8" hoses, PN 4203576. One to 7", the other to 6". d. Shorten both 6" convolute sleeves, PN 4279993. One to 5", the other to 4". e. Slide the shortened 5" convolute, PN 4279993, over the shortened 7" hose, PN 4203576, and install from the reservoir outlet nipple to the carburetor fuel tube (Figure 4-B). Clamp with PN 6500651 at each end. CAUTION: BE SURE TO ROUTE THIS HOSE AND SLEEVE ASSEMBLY UNDER THE 8" RESERVOIR RETURN HOSE ASSEMBLY. FAILURE TO DO SO MAY RESULT IN HOSE KINKING. NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE, SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. f. Slide the shortened 4" convolute over the shortened 6" hose, and install from the fuel pump outlet tube to the reservoir inlet nipple (Figure 4-B). Clamp with PN 6500651 at each end. 4. On 4 x 4 Models a. Install return hose assembly, PN 4418005, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4621 b. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 4203576. c. Install one 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the fuel pump outlet tube to the reservoir inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). d. Install the other 5/16" x 8" hose, PN 4203576, (with convolute sleeve PN 4279993) from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 5. Tighten all hose clamps to 10 inch pounds. FIGURE 7 6. Type in Authorized Modification Label, PN 4275086, as shown in Figure 7 and attach near VECI label. 7. For all models except 1981-1984 equipped with Carter thermoquad 4BBL carburetor: Reconnect battery. Start the engine and inspect the entire system for fuel leaks and proper wire and hose routing. F. 1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (PN 4397639) 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4622 FIGURE 5 - FUEL PRESSURE REGULATOR INSTALLATION 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6022254 (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6022254 THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference to nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose to regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. 6. Reconnect the battery terminal. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. POLICY: Reimbursable within the provisions of the warranty Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4623 TIME ALLOWANCE: Refer to existing Labor Operation Time Schedule Labor Operation No. 14-70-17-93 - All . . . . . . . . . . . 2.1 Hrs. 14-70-17-50 - Add with Carter . . . . . 0.4 Hrs. Thermoquad Carburetor FAILURE CODE: AM - Authorized Modification Parts List - Vapor Lock Packages - 20, 30 & 35 Gallon Fuel Tanks PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 20 GALLON FUEL TANK PACKAGE PART NO. 4364384 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075484 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 30 GALLON FUEL TANK PACKAGE PART NO. 4364385 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075485 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 4) 4306968 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 185386 > Dec > 86 > Fuel System - Engine Vapor Lock > Page 4624 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Seal - Fuel Tank Gauge 4185002 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 D & W MODEL TRUCK - 35 GALLON FUEL TANK PACKAGE PART NO. 4364386 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075439 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Wiring Harness 4362284 1 Body Wiring Harness 4362286 1 Control Module 5226640 20 Tie Wrap 6015756 1 10-Amp Fuse 6101135 1 Fuel Reservoir/Filter & Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6550651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 6022777 1 Template (4 x 4) 4418013 2 Hose - 5/16" x 8" Long 4203576 1 Hose & Sleeve Assembly - 1/4" x 10" Long 4418005 2 Convolute Tubing - 6" Long 4279993 1 Template (4 x 2) 1981 to 1985 Vehicles Only 4418042 1 Template (4 x 2) 1987 Vehicles Only 4418412 1 Fuel Pump-to-Reservoir Tube Assembly (4 x 2) 4306967 1 Gasket - Fuel Tank Gauge 3730757 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. Part List Fuel Pressure Regulator Package For 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO. 4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock Technical Service Bulletin # 181985A Date: 851201 Fuel System - Vapor Lock Models 1981-1985 Van & Wagon Models Equipped With 5.2L or 5.9L Engine Subject Vapor Lock Index DRIVEABILITY Date December 20, 1985 No. 18-19-85 REVISION A P-4782-C This bulletin supersedes Technical Service Bulletin #18-19-85 which should be removed from your files. The model application has been expanded to include 1981 and 1982 model years. SYMPTOM/CONDITION Engine performance is gradually reduced in high ambient temperature or high altitude driving due to a drop in fuel pressure, which starves engine for fuel (goes lean). Engine may not start until fuel system components cool off. DIAGNOSIS The following are characteristics of vapor lock and should be observed on a fully warmed up engine. (Vapor lock does not affect cold engine driveability.) ^ Occurs after hot soak, prolonged idle, or highway speeds at any throttle opening. ^ Sag due to lean mixture. ^ No black smoke at tailpipe. ^ Fuel pressure drops to 0. ^ Carburetor air horn dry. ^ No accelerator pump discharge. ^ May not start until engine cools. ^ Engine may not sustain heavy loads. PARTS REQUIRED ORDER ONE OF THE FOLLOWING TWO PART NUMBERS: Vapor Lock Package With 22 Gallon Fuel Tank PN 4397611 Vapor Lock Package With 36 Gallon Fuel Tank PN 4397612 ADDITIONAL PARTS INFORMATION ON NEXT PAGE 1981-1984 models equipped with Carter Thermoquad 4BBL carburetor must order the following package in addition to the vapor lock package. Fuel Pressure Regulator Package PN 4397639 All vehicles equipped with dual air conditioning, without electrically heated rear window defroster, and with 60 amp alternator must order the following package in addition to the vapor lock package. If vehicle is equipped with a 114 amp alternator, do not order this package or make any changes to the charging system. 1 78 AMP Alternator Package PN 4397615 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4629 Refer to parts list for contents of each package. Must be ordered separately: 1 Authorized Modification Label PN 4275086 NOTE: IT IS IMPORTANT THAT THE SPECIFIED FUEL TANK SIZE APPLICATION PACKAGE BE SELECTED. THE USE OF AN IMPROPER PART NUMBER PACKAGE MAY CAUSE THE VEHICLE TO RUN OUT OF FUEL WELL BEFORE THE GAUGE READS EMPTY. REPAIR PROCEDURE A.Engine Compartment Harness Pn 4362295 1. Disconnect the battery. 2. Remove engine side of bulkhead connector. Depress fingers on instrument panel half of bulkhead connector, and push connector back through the hole into the passenger compartment. FIGURE 1A - ENGINE COMPARTMENT WIRING 3. Remove engine cover. Install the bare eyelet terminal of overlay harness, PN 4362295, to the negative terminal of the ignition coil as shown in Figure 1-A. FIGURE 1B - ENGINE COMPARTMENT WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4630 4. Route and secure the engine overlay harness, PN 4362295, along the existing main engine wiring harness using the existing wiring clips and two tie wraps, PN 6015756 (Figure 1-B). FIGURE 1C - ENGINE COMPARTMENT WIRING 5. Route and secure the engine overlay harness, PN 4362295, along the existing headlamp-to-dash main engine wiring harness to the bulkhead connector using the existing wiring clips and three tie wraps, PN 6015756 (Figure 1-C). Loop and tape any excess wire of the engine overlay harness. FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 6. Coat the bare blade terminal of the engine overlay harness, PN 4362295, liberally with Mopar multi-purpose grease PN 4318063, and snap into cavity #14 of the engine side of the bulkhead connector (Figure 1-D). B.Instrument Panel Harnesses Pn 4362289, All Models Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4631 FIGURE 2A - TERMINAL END OF BULKHEAD CONNECTOR (INSTRUMENT PANEL SIDE) 1. Remove instrument panel left lower trim panel. 2. Insert two bare terminals from instrument panel overlay harness, PN 4362289, into the instrument panel side of the bulkhead connector (Figure 2-A). a. Gray with black tracer wire into cavity #14. b. Dark green wire into cavity #13. INSTRUMENT PANEL WIRING 3. Secure bare eyelet ground terminal (white with black tracer wire) from instrument panel overlay harness, PN 4362289, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). NOTE: CERTAIN VEHICLES ARE ALREADY EQUIPPED WITH THE GROUND SCREW. IF SO, DISCARD THE SUPPLIED SCREW. FIGURE 2C - INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4632 FIGURE 2D - INSTRUMENT PANEL WIRING 4. Disconnect the arced grey 7-way ignition switch connectors and remove the orange wire from the instrument panel side (Figure 2-C). Install the extracted terminal (orange wire) into the natural colored 1-way connector supplied with instrument panel overlay harness, PN 4362289. Install the bare terminal (orange wire) from the instrument panel overlay harness, PN 4362289, into the vacated cavity in the ignition switch connector. Reconnect the natural colored 1-way connectors supplied with the instrument panel overlay harness, PN 4362289, and reconnect the ignition switch connectors (Figure 2-C and 2-D). FIGURE 2E - TYPICAL CONTROL MODULE MOUNTING 5. Connect the control (auto shut-down) module, PN 5226640, to the natural colored 8-way connector from instrument panel overlay harness, PN 4362289. Secure the module onto the main instrument panel wiring harness with a tie wrap, PN 6015756, close to the bulkhead connector (Figure 2-E). INSTRUMENT PANEL WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4633 FIGURE 2D - INSTRUMENT PANEL WIRING FIGURE 2F - INSTRUMENT PANEL WIRING 6. Route the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289, to the back of the brake bracket for mating in a later step (Figures 2-B, 2-D, and 2-F). Secure instrument panel overlay harness, PN 4362289, using tie wrap, PN 6015756, to keep it clear of any possible interferences. Only one of the following installation procedures (Step 7) will be used. Take notice of which one applies to the vehicle being repaired. 7. Without Auxiliary Air Conditioning and/or Heater - Jumper Harness PN 4362291 a. Remove instrument panel hood and bezel assembly and remove radio. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4634 FIGURE 2D - INSTRUMENT PANEL WIRING b. Route instrument panel jumper harness, PN 4362291, from the back of the brake bracket to the existing 3-way red molded connector. Secure by using existing wiring clips (Figure 2-D). c. Insert the bare bullet terminal (black with white tracer wire) from instrument panel jumper harness, PN 4362291, into the existing 3-way red molded connector from the main instrument panel wiring harness (Figure 2-D). d. Mate the orange colored 1-way connector from instrument panel jumper harness, PN 4362291, to the orange colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). e. Reinstall instrument panel hood and bezel assembly and install radio. FIGURE 2F - INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater and Power Windows - Jumper Harness PN 4362292 a. Disconnect from each other, the two existing brown colored 1-way connectors located near the left instrument panel vent (Figure 2-F). Reconnect these two brown colored 1-way connectors to the two brown colored 1-way connectors from instrument panel jumper harness, PN 4362292 (Figure 2-F). b. Mate the orange colored 1-way connector from the instrument panel jumper harness, PN 4362292, to the orange colored 1-way connector from instrument panel overlay harness, PN 4362289 (Figure 2-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4635 INSTRUMENT PANEL WIRING 7. With Auxiliary Air Conditioning and/or Heater Without Power Windows - Relay Harness PN 4362290 a. Remove instrument panel hood and bezel assembly. Remove radio. b. Install the ignition switch protection relay, PN 4162597, to the back of the brake bracket (mounting location shown in Figure 2-B) and attach instrument panel relay harness, PN 4362290, to relay. c. Secure bare eyelet ground terminal (white wire) from instrument panel relay harness, PN 4362290, with screw, PN 9414722, to the back of the brake bracket (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING d. Route the dark blue wire from the instrument panel relay harness, PN 4362290 to the existing 3-way red molded connector using existing wiring clips. Insert bullet terminal (dark blue wire) into red molded connector (Figure 2-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4636 INSTRUMENT PANEL WIRING e. Insert bare bullet terminal (red wire) from instrument panel relay harness, PN 4362290, into the existing 3-way yellow molded connector from the main instrument panel wiring harness (Figure 2-B). FIGURE 2D - INSTRUMENT PANEL WIRING f. Mate the orange colored 1-way connector from instrument panel relay harness, PN 4362290, to the colored 1-way connector from the instrument panel overlay harness, PN 4362289 (Figure 2-D). g. Install the instrument panel left lower trim panel, instrument panel hood, bezel assembly and radio. C.In-Tank Fuel Pump Installation 1. Remove the fuel tank gauge unit from the fuel tank per the service manual procedure and discard. Install the new seal and gauge/pump unit from the applicable kit. Use extreme caution to protect the float and gauge assembly during installation into the fuel tank. 2. With the fuel tank partially raised, connect the fuel tank vent hose, fuel return, and fuel supply hoses. Secure the hoses with the hose clamps provided. 3. Feed red and yellow molds of body wiring harness, PN 4362293, through slot in the crossmember. Remove existing screw for gauge unit ground. Install eyelet terminal of harness, PN 4362293 (and ground eyelet terminal of 36 gallon tank gauge/pump unit) and torque ground screw to 36 inch pounds. CAUTION: GROUND SCREW MUST BE TIGHTENED SECURELY TO OPERATE ELECTRIC PUMP AND GAUGE UNIT. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4637 FIGURE 3A - BODY WIRING FIGURE 3B - BODY WIRING Install red mold of body harness, PN 4362293, onto red stud of gauge/pump unit. Install yellow mold of harness, PN 4362293, onto black stud of gauge/pump unit (figure 3-a or 3-b). Install molded blade terminal of harness, PN 4362293, onto blade terminal of 22 gallon gauge unit only. NOTE: PREVIOUS GAUGE UNIT GROUND WILL NOT BE USED ON 22 GALLON GAUGE/PUMP UNIT. ON 36 GALLON GAUGE PUMP UNIT, THE GROUND WIRE ON HARNESS PN 4362293 WILL NOT BE USED. CAUTION: INCORRECT WIRING CONNECTIONS WILL CAUSE THE FUEL LEVEL GAUGE UNIT AND/OR CLUSTER GAUGE TO FAIL AND THE ELECTRIC PUMP TO BE INOPERATIVE. Set aside the rest of harness, PN 4362293, to assure wiring is not pinched when reinstalling fuel tank. 4. Reinstall fuel tank to original position. D.Body Wiring Harness Pn 4362293 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4638 FIGURE 3C - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4639 FIGURE 3-F - BODY WIRING 1. Vehicles With 36 Gallon Tank Route harness, PN 4362293, to the right (passenger) side of vehicle along the fuel line tubes and tie wrap (1). At right frame rail, route harness forward to next crossmember (Figures 3-C and 3-E). Tie wrap harness in three (3) places. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4640 FIGURE 3D - BODY WIRING Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4641 FIGURE 3-F - BODY WIRING Vehicles With 22 Gallon Tank Route harness, PN 4362293, along right frame rail following brake lines (Figures 3-D and 3-E). Tie wrap in two (2) places. NOTE: HARNESS MUST BE ABOVE SHOCK STRUT WITH EITHER 36 OR 22 GALLON TANK. 2. At crossmember, route harness to the left rail following existing brake lines and tie wrap in two (2) places. At left rail, route harness forward through access holes following existing brake lines. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4642 FIGURE 3-F - BODY WIRING NOTE: HARNESS SHOULD BE TIGHT IN THIS AREA THE WRAP IN FOUR (4) PLACES (FIGURE 3-E). 3. At engine compartment, route harness through existing speedometer cable clips to bulkhead connector. If excess wiring exists; loop, tie wrap (2), and install into existing clip (Figure 3-F). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4643 FIGURE 1D - TERMINAL END OF BULKHEAD CONNECTOR (ENGINE COMPARTMENT SIDE) 4. Plug bare terminal of harness, PN 4362293, into cavity #13 of the bulkhead connector (Figure 1-D). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4644 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4645 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4646 FIGURE 9 - ELECTRIC FUEL PUMP WIRING DIAGRAMW/AUX A/C & HEATER-W/O POWER WINDOWS 5. For all vehicles except those which require a 78 amp alternator package: Reinstall instrument panel side, then engine compartment side of bulkhead connector and torque bolt to 40 inch pounds. NOTE: REFER TO FIGURES 7, 8, OR 9 FOR OVERALL WIRING DIAGRAMS. E.Engine Compartment Fuel Reservoir/Filter Lnstallation Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4647 FIGURE 4-A - DRILLING HOLES TO MOUNT FUEL RESERVOIR/FILTER 1. Using template, PN 4418011, mark and drill (from engine side of passenger side chassis rail) two (2) holes .290" diameter (L size drill) as shown in Figure 4-A. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4648 FIGURE 4B - Mounting Fuel Resevoir/Filter 2. Install supplied fuel reservoir/filter, PN 4418012, using two (2) self-tapping screws, PN 6022777 (Figure 4-B). Screws must be tightened to 95 +/- 10 inch pounds. NOTE: RUBBER SPLASH SHIELD MAY HAVE TO BE CUT OUT AROUND FUEL RESERVOIR. 3. Remove and discard the fuel pump outlet tube, return hose, and fuel filter with rubber hoses and clamps. Install the fuel pump-to-reservoir tube, PN 4306968 (Figure 4-B). 4. Install return hose assembly, PN 4418006, from the fuel reservoir return nipple to the chassis tube, and clamp with PN 6500650 at each end (Figure 4-B). 5. Slide both 6" pieces of convolute sleeve, PN 4279993, over each 5/16" x 8" hose, PN 42O3576. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4649 FIGURE 4B - Mounting Fuel Resevoir/Filter 6. Install one 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the fuel pump outlet tube to the reservoir/filter inlet nipple, and clamp with PN 6500651 at each end (Figure 4-B). 7. Install the other 5/16" x 8" hose, PN 4203576 (with convolute sleeve PN 4279993), from the reservoir outlet nipple to the carburetor fuel tube, and clamp with PN 6500651 at each end (Figure 4-B). NOTE: IF EQUIPPED WITH THERMOQUAD CARBURETOR, DO NOT INSTALL HOSE TO CARBURETOR TUBE SINCE FUEL TUBE WILL BE CHANGED IN SECTION F. 8. Tighten all hose clamps to 10 inch pounds. FIGURE 10 9. Type Authorized Modification Label, PN 4275086, as shown in Figure 10 and attach near VECI label. 10. For all models except 1981-1984 equipped with Carter Thermoquad 4BBL carburetor or dual air conditioning units without electrically Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4650 heated rear window defroster. Reconnect battery. Start the engine, and inspect the entire system for fuel leaks and proper wire and hose routing. 11. Reinstall engine cover. F.1981-1984 Models Equipped With Carter Thermoquad 4BBL Carburetor Only - Fuel Pressure Regulator Package Installation (Pn 4397 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1. Remove the original carburetor inlet fuel tube and fuel tube clip (attached to boss on intake manifold) and discard. 2. Fasten the bracket, PN 4418010, to the fuel pressure regulator, PN 4418009, using the two (2) self-tapping screws supplied, PN 6033066 (Figure 5). NOTE: BE SURE THAT OUTLET SIDE OF REGULATOR FACES THE CARBURETOR INLET. 3. At the tapped boss on the right side of the intake manifold, install bracket and fuel pressure regulator assembly using the screw and washer, PN 6O22254, (Figure 5). NOTE: IF THERE EXISTS AN A/C ALTERNATOR BRACKET SUPPORT STRUT IN THIS LOCATION, THEN LOOSEN THE OPPOSITE END OF THE STRUT FIRST. REMOVE AND DISCARD THE SCREW AND WASHER HOLDING THE STRUT TO THE MANIFOLD. SLIDE REGULATOR BRACKET UNDER THE SUPPORT STRUT, AND SECURE WITH SUPPLIED SCREW AND WASHER, PN 6O22254. THEN TIGHTEN THE OPPOSITE END OF THE STRUT. CAUTION: BE EXTREMELY CAREFUL NOT TO DAMAGE OR PINCH ANY HARNESS IN THE AREA. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4651 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 4. Install new tube, PN 4418008, from the regulator outlet to the carburetor inlet. Install new tube, PN 4418014, from the reservoir outlet hose to the regulator inlet (Figure 5). Be sure that the tube passes through the clip mounted on the mechanical fuel pump attachment bolt. Slightly compress clip to secure tube away from any possible interference with nearby components. 5. Install clamp, PN 6500651, as shown in Figure 5 (filter outlet hose-to-regulator inlet tube). Rotate clamp so that it is not in contact with any other surface. Torque to 10 inch pounds. For all models except those equipped with dual air conditioning units, without electrically heated rear window defroster and with 60 amp alternator: 6. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 7. Reinstall engine cover. G.Vehicles Equipped With Dual Air Conditioning Units, Without Electrically Heated Rear Defroster, and With 60 Amp Alternator. I Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4652 HEADLAMP AND DASH WIRING ASSEMBLY 1. Disconnect the battery positive lead (single in-line connection) from the headlamp and dash wiring assembly (Figure 6-A). FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 2. Remove the following wires from the engine compartment side of the bulkhead connector (Figure 6-B). a. Red wire from cavity #39 (ammeter). b. Black wire from cavity #33 (ammeter). Cut off the terminals and wrap tape around each end of both wires to insure that shorting cannot occur. Then tape the wrapped wires back against the main harness. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4653 FIGURE 6-C - 78 AMP ALTERNATOR WIRING 3. Remove the alternator output wire (heavy gauge) from the 60 amp alternator (Figure 6-C). Cut the wire off leaving approximately three (3) inches of wire extending out of the main harness. Tape the end of the lead thoroughly. Then fold and tape the lead back against the main harness to prevent shorting. 4. Remove 60 amp alternator assembly and install 78 amp alternator assembly, PN 4111204, per the service manual alternator replacement procedure. HEADLAMP AND DASH WIRING ASSEMBLY Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4654 FIGURE 6-B - TERMINAL END OF BULKHEAD CONNECTOR(ENGINE COMPARTMENT SIDE) 5. Beginning at the bulkhead, route and connect the wiring assembly, PN 4362343, as shown in Figure 6-A. Use the existing clip for main harness and tie wrap with three (3) tie wraps, PN 6015756. Insert the two bare terminals from alternator overlay wiring harness, PN 4362343, as shown in Figure 6-B as follows: NOTE: THE 4362343 ALTERNATOR OVERLAY HARNESS WAS MANUFACTURED WITH THE RED AND BLACK WIRES REVERSED. THEREFORE, IT WILL BE NECESSARY TO INSTALL THE BLACK WIRE (LABELED RED) INTO CAVITY #39 (RED WIRE PREVIOUSLY REMOVED), AND THE RED WIRE (LABELED BLACK) INTO CAVITY #33 (BLACK WIRE PREVIOUSLY REMOVED). FAILURE TO REVERSE THESE TWO WIRES WILL RESULT IN THE AMMETER SHOWING THE OPPOSITE CHARGE INDICATION. a. Red wire into cavity #33 (ammeter) - (labeled as black wire). b. Black wire into cavity #39 (ammeter) - (labeled as red wire). 6. Install wiring assembly, PN 4362343, alternator output terminal to new 78 amp alternator. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4655 FIGURE 6A1 7. Connect the battery positive lead and the headlamp and dash wiring assembly lead to those of the alternator overlay wiring assembly, PN 4362343, as shown in circled view of Figure 6-A. 8. Reinstall instrument panel half, then engine compartment half of bulkhead connector and torque to 40 inch pounds. 9. Reconnect battery. Check wire and hose routing, start the engine, and inspect the entire system for fuel leaks. 10. Reinstall engine cover. POLICY: Reimbursable within the provisions of the warranty and repair manual. TIME ALLOWANCE: Labor Operation No. 14-70-17-94 - All 2.5 Hrs. Optional Equipment: 14-70-17-60 - Carter Thermoquad Carburetor 0.5 Hrs. 14-70-17-61 - With Auxiliary A/C - Without Elec. 0.7 Hrs. Rear Window Defroster 14-70-17-62 - Without Auxiliary A/C 0.3 Hrs. 14-70-17-63 - With Auxiliary A/C - Without 0.4 Hrs. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4656 Power Windows FAILURE CODE: AM - Authorized Modification Part List VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 22 GALLON FUEL TANK PACKAGE PART NO. 4397611 QTY PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075432 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Seal - Fuel Tank Gauge 3404451 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* *It may be necessary to order clamp separately on early released packages. PARTS LIST VAPOR LOCK PACKAGE 1981-1985 B MODEL TRUCK - 36 GALLON FUEL TANK PACKAGE PART NO. 4397612 QTY. PART NAME PART NO. 1 Gauge/Pump Unit Assembly 4075436 1 Engine Compartment Wiring Harness 4362295 1 Instrument Panel Overlay Harness 4362289 1 Instrument Panel Relay Harness 4362290 1 Instrument Panel Jumper Harness 4362291 1 Instrument Panel Jumper Harness 4362292 1 Body Wiring Harness 4362293 1 Ignition Switch Protection Relay 4162597 1 Control Module 5226640 1 Ground Screw 9414722 20 Tie Wrap 6015756 1 Fuel Reservoir/Filter and Bracket Assembly 4418012 1 Fuel Pump-to-Reservoir Tube Assembly 4306968 5 Hose Clamp 5/16" 6500651 3 Hose Clamp 1/4" 6500650 2 Screw - Self-Tapping 5/16" - 18 x .75 Long 6022777 1 Template 4418011 2 Hose - 5/16" x 8" Long 4203576 1 Hose and Sleeve Assembly - 1/4" x 8" Long 4418006 2 Convolute Tubing - 6" Long 4279993 1 Gasket - Fuel Tank Sending Unit 4115209 1 Hose Clamp 1/2" - Filler Neck Vent Tube 2448761* Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4657 *It may be necessary to order clamp separately on early released packages. PARTS LIST FUEL PRESSURE REGULATOR PACKAGE FOR 1981-1984 5.2L & 5.9L ENGINES WITH CARTER THERMOQUAD 4BBL CARBURETORS PACKAGE PART NO.4397639 QTY. PART NAME PART NO. 1 Pressure Regulator Assembly 4418009 1 Pressure Regulator Bracket 4418010 1 Screw & Washer Bracket to Intake Manifold 6022254 2 Screw - Pressure Regulator to Bracket 6033066 1 Tube - Reservoir/Filter Hose to Pressure Regulator 4418014 1 Tube - Pressure Regulator to Carburetor 4418008 1 Clamp - 5/16" 6500651 PARTS LIST 78 AMP ALTERNATOR PACKAGE FOR 1981-1985 B MODEL TRUCKS WITH 5.2L OR 5.9L ENGINES PACKAGE PART NO. 4397615 QTY. PART NAME PART NO. 1 78 AMP Alternator Assembly - Complete 4111204 1 Alternator Overlay Wiring Harness 4362343 4 Tie Wrap 6015756 1 Gasket - Bulkhead Connector 4055399 FIGURE 4B - Mounting Fuel Resevoir/Filter 1. Fuel Filter/ Reservoir - 4418012 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 181985A > Dec > 85 > Fuel System - Vapor Lock > Page 4658 2. Screw - Self Tapping - 6022777 (2 Req.) 3. Tube Assy - Fuel Pump to Reservoir - 4306968 4. Return Hose & Sleeve Assy - 4418006 5. Hose Clamps - 6500650 (2 Req.) - 1/4" 6. Hose-Fuel Pump Outlet to Reservoir Inlet - 4203576 7. Hose-Reservoir Outlet to Carburetor or Regulator Fuel Tube - 4203576 8. Hose Clamps - 6500651 (4 Req.) - 5/16" Included but not shown: 2 piece Convolute Tubing - 4279993 FIGURE 5FUEL PRESSURE REGULATOR INSTALLATION 1 SCREW & WASHER - 6022254 2 REGULATOR BRACKET - 4418010 3 REGULATOR - 4418OD9 4 TUBE - REGULATOR TO CARB - 4418008 5 TUBE - RESERVOIR HOSE TO REGULATOR - 4418014 6 SCREW (2 EA.) - REGULATOR TO BRACKET - 6033066 7 CLAMP (5116) - 6500651 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 4661 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 4662 Fuel Gauge Sender: Electrical Diagrams Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 4663 Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 4664 Fig. 15 Fuel Gauge & Seatbelt Warning System Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 4665 Fuel Gauge Sender: Testing and Inspection A hinged float arm in the fuel tank contacts a variable resistor in the gauge sending unit. The varying resistance in the fuel gauge circuit registers on the instrument panel gauge. Resistance in the circuit is lowest when the fuel tank is full and float arm is raised. The resulting high current flow causes the instrument panel gauge to indicate Full. TROUBLESHOOTING 1. Disconnect electrical connector from fuel tank sending unit and attach connector to a known good sending unit. 2. Connect a jumper wire between sending unit fuel pickup tube and a good ground. 3. Secure sending unit float arm in the empty stop position and turn ignition On. Within two minutes, the gauge should read Empty, plus one pointer width or minus two pointer widths. 4. Move float arm and secure in the full stop position. Within two minutes, the gauge should read Full, plus two pointer widths, or minus one pointer width. 5. If fuel gauge does not operate as specified, check the following: a. Wiring and electrical connections between sending unit and connector. b. Wiring and electrical connections between connector and printed circuit board terminals. c. Circuit continuity between printed circuit board terminals and gauge terminals. d. Voltage limiter performance. 6. If fuel gauge operates as specified with known good sending unit, check fuel tank and original sending unit as follows: a. Remove sending unit from fuel tank. b. Connect sending unit wire and jumper wire as previously described. c. If fuel gauge now operates as specified, check sending unit for damage, obstructions or improper installation and correct as necessary. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4670 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4671 Fig. 8 Cargo, Dome & Map Lamps Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Parking Brake Warning Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4676 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4677 Parking Brake Warning Switch: Electrical Diagrams Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4678 Fig. 7 Brake, Oil & Temperature Switch Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Cable > Component Information > Description and Operation Speedometer Cable: Description and Operation The following material covers only that service on speedometers which is feasible to perform. Repairs on the units themselves are not included as they require special tools and extreme care when making repairs and adjustments that only an experienced speedometer mechanic should attempt. The speedometer has two main parts, the speedometer head and the speedometer drive cable. When the speedometer fails to indicate speed or mileage, the cable or cable housing is probably broken. SPEEDOMETER CABLE Most cables are broken due to lack of lubrication, or a sharp bend or kink in the housing. A cable might break because of the speedometer head mechanism binds. In such cases, the speedometer head should be repaired or replaced before a new cable or housing is installed. A "jumpy" pointer condition, together with a scraping noise, is due, in most instances, to a dry or kinked speedometer cable. The kinked cable rubs on the housing and winds up, slowing down the pointer. The cable then unwinds and the pointer "jumps." To check for kinks, remove the cable, lay it on a flat surface and twist one end with the fingers. If it turns over smoothly the cable is not kinked. But if part of the cable flops over as it is twisted, the cable is kinked and should be replaced. LUBRICATION The speedometer cable should be lubricated with special cable lubricant. Fill the ferrule on the upper end of the housing with the cable lubricant. Insert the cable in the housing, starting at the upper end. Turn the cable around carefully while feeding it into the housing. Repeat filling the ferrule except for the last six inches of cable. Too much lubricant at this point may cause the lubricant to work into the speedometer head. INSTALLING CABLE During installation, if the cable sticks when inserted in the housing and will not go through, the housing is damaged inside or kinked. Be sure to check the housing from one end to the other. Straighten any sharp bends by relocating clamps or elbows. Replace housing if it is badly kinked or broken. Position the cable and housing so that they lead into the head as straight as possible. Check the new cable for kinks before installing it. Use wide, sweeping, gradual curves where the cable comes out of the transmission and connects to the head so the cable will not be damaged during installation. Arrange the housing so it does not lean against the engine because heat from the engine may dry out the lubricant. If inspection indicates that the cable and housing are in good condition, yet pointer action is erratic, check the speedometer head for possible binding. The speedometer drive pinion should also be checked. If the pinion is dry or its teeth are stripped, the speedometer may not register properly. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Cable > Component Information > Description and Operation > Page 4682 Speedometer Cable: Testing and Inspection The following material covers only that service on speedometers which is feasible to perform. Repairs on the units themselves are not included as they require special tools and extreme care when making repairs and adjustments that only an experienced speedometer mechanic should attempt. The speedometer has two main parts, the speedometer head and the speedometer drive cable. When the speedometer fails to indicate speed or mileage, the cable or cable housing is probably broken. SPEEDOMETER CABLE Most cables are broken due to lack of lubrication, or a sharp bend or kink in the housing. A cable might break because of the speedometer head mechanism binds. In such cases, the speedometer head should be repaired or replaced before a new cable or housing is installed. A "jumpy" pointer condition, together with a scraping noise, is due, in most instances, to a dry or kinked speedometer cable. The kinked cable rubs on the housing and winds up, slowing down the pointer. The cable then unwinds and the pointer "jumps." To check for kinks, remove the cable, lay it on a flat surface and twist one end with the fingers. If it turns over smoothly the cable is not kinked. But if part of the cable flops over as it is twisted, the cable is kinked and should be replaced. LUBRICATION The speedometer cable should be lubricated with special cable lubricant. Fill the ferrule on the upper end of the housing with the cable lubricant. Insert the cable in the housing, starting at the upper end. Turn the cable around carefully while feeding it into the housing. Repeat filling the ferrule except for the last six inches of cable. Too much lubricant at this point may cause the lubricant to work into the speedometer head. INSTALLING CABLE During installation, if the cable sticks when inserted in the housing and will not go through, the housing is damaged inside or kinked. Be sure to check the housing from one end to the other. Straighten any sharp bends by relocating clamps or elbows. Replace housing if it is badly kinked or broken. Position the cable and housing so that they lead into the head as straight as possible. Check the new cable for kinks before installing it. Use wide, sweeping, gradual curves where the cable comes out of the transmission and connects to the head so the cable will not be damaged during installation. Arrange the housing so it does not lean against the engine because heat from the engine may dry out the lubricant. If inspection indicates that the cable and housing are in good condition, yet pointer action is erratic, check the speedometer head for possible binding. The speedometer drive pinion should also be checked. If the pinion is dry or its teeth are stripped, the speedometer may not register properly. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Cable > Component Information > Description and Operation > Page 4683 Speedometer Cable: Service and Repair The following material covers only that service on speedometers which is feasible to perform. Repairs on the units themselves are not included as they require special tools and extreme care when making repairs and adjustments that only an experienced speedometer mechanic should attempt. The speedometer has two main parts, the speedometer head and the speedometer drive cable. When the speedometer fails to indicate speed or mileage, the cable or cable housing is probably broken. SPEEDOMETER CABLE Most cables are broken due to lack of lubrication, or a sharp bend or kink in the housing. A cable might break because of the speedometer head mechanism binds. In such cases, the speedometer head should be repaired or replaced before a new cable or housing is installed. A "jumpy" pointer condition, together with a scraping noise, is due, in most instances, to a dry or kinked speedometer cable. The kinked cable rubs on the housing and winds up, slowing down the pointer. The cable then unwinds and the pointer "jumps." To check for kinks, remove the cable, lay it on a flat surface and twist one end with the fingers. If it turns over smoothly the cable is not kinked. But if part of the cable flops over as it is twisted, the cable is kinked and should be replaced. LUBRICATION The speedometer cable should be lubricated with special cable lubricant. Fill the ferrule on the upper end of the housing with the cable lubricant. Insert the cable in the housing, starting at the upper end. Turn the cable around carefully while feeding it into the housing. Repeat filling the ferrule except for the last six inches of cable. Too much lubricant at this point may cause the lubricant to work into the speedometer head. INSTALLING CABLE During installation, if the cable sticks when inserted in the housing and will not go through, the housing is damaged inside or kinked. Be sure to check the housing from one end to the other. Straighten any sharp bends by relocating clamps or elbows. Replace housing if it is badly kinked or broken. Position the cable and housing so that they lead into the head as straight as possible. Check the new cable for kinks before installing it. Use wide, sweeping, gradual curves where the cable comes out of the transmission and connects to the head so the cable will not be damaged during installation. Arrange the housing so it does not lean against the engine because heat from the engine may dry out the lubricant. If inspection indicates that the cable and housing are in good condition, yet pointer action is erratic, check the speedometer head for possible binding. The speedometer drive pinion should also be checked. If the pinion is dry or its teeth are stripped, the speedometer may not register properly. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation Speedometer Head: Description and Operation The following material covers only that service on speedometers which is feasible to perform. Repairs on the units themselves are not included as they require special tools and extreme care when making repairs and adjustments that only an experienced speedometer mechanic should attempt. The speedometer has two main parts, the speedometer head and the speedometer drive cable. When the speedometer fails to indicate speed or mileage, the cable or cable housing is probably broken. SPEEDOMETER CABLE Most cables are broken due to lack of lubrication, or a sharp bend or kink in the housing. A cable might break because of the speedometer head mechanism binds. In such cases, the speedometer head should be repaired or replaced before a new cable or housing is installed. A "jumpy" pointer condition, together with a scraping noise, is due, in most instances, to a dry or kinked speedometer cable. The kinked cable rubs on the housing and winds up, slowing down the pointer. The cable then unwinds and the pointer "jumps." To check for kinks, remove the cable, lay it on a flat surface and twist one end with the fingers. If it turns over smoothly the cable is not kinked. But if part of the cable flops over as it is twisted, the cable is kinked and should be replaced. LUBRICATION The speedometer cable should be lubricated with special cable lubricant. Fill the ferrule on the upper end of the housing with the cable lubricant. Insert the cable in the housing, starting at the upper end. Turn the cable around carefully while feeding it into the housing. Repeat filling the ferrule except for the last six inches of cable. Too much lubricant at this point may cause the lubricant to work into the speedometer head. INSTALLING CABLE During installation, if the cable sticks when inserted in the housing and will not go through, the housing is damaged inside or kinked. Be sure to check the housing from one end to the other. Straighten any sharp bends by relocating clamps or elbows. Replace housing if it is badly kinked or broken. Position the cable and housing so that they lead into the head as straight as possible. Check the new cable for kinks before installing it. Use wide, sweeping, gradual curves where the cable comes out of the transmission and connects to the head so the cable will not be damaged during installation. Arrange the housing so it does not lean against the engine because heat from the engine may dry out the lubricant. If inspection indicates that the cable and housing are in good condition, yet pointer action is erratic, check the speedometer head for possible binding. The speedometer drive pinion should also be checked. If the pinion is dry or its teeth are stripped, the speedometer may not register properly. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation > Page 4687 Speedometer Head: Testing and Inspection The following material covers only that service on speedometers which is feasible to perform. Repairs on the units themselves are not included as they require special tools and extreme care when making repairs and adjustments that only an experienced speedometer mechanic should attempt. The speedometer has two main parts, the speedometer head and the speedometer drive cable. When the speedometer fails to indicate speed or mileage, the cable or cable housing is probably broken. SPEEDOMETER CABLE Most cables are broken due to lack of lubrication, or a sharp bend or kink in the housing. A cable might break because of the speedometer head mechanism binds. In such cases, the speedometer head should be repaired or replaced before a new cable or housing is installed. A "jumpy" pointer condition, together with a scraping noise, is due, in most instances, to a dry or kinked speedometer cable. The kinked cable rubs on the housing and winds up, slowing down the pointer. The cable then unwinds and the pointer "jumps." To check for kinks, remove the cable, lay it on a flat surface and twist one end with the fingers. If it turns over smoothly the cable is not kinked. But if part of the cable flops over as it is twisted, the cable is kinked and should be replaced. LUBRICATION The speedometer cable should be lubricated with special cable lubricant. Fill the ferrule on the upper end of the housing with the cable lubricant. Insert the cable in the housing, starting at the upper end. Turn the cable around carefully while feeding it into the housing. Repeat filling the ferrule except for the last six inches of cable. Too much lubricant at this point may cause the lubricant to work into the speedometer head. INSTALLING CABLE During installation, if the cable sticks when inserted in the housing and will not go through, the housing is damaged inside or kinked. Be sure to check the housing from one end to the other. Straighten any sharp bends by relocating clamps or elbows. Replace housing if it is badly kinked or broken. Position the cable and housing so that they lead into the head as straight as possible. Check the new cable for kinks before installing it. Use wide, sweeping, gradual curves where the cable comes out of the transmission and connects to the head so the cable will not be damaged during installation. Arrange the housing so it does not lean against the engine because heat from the engine may dry out the lubricant. If inspection indicates that the cable and housing are in good condition, yet pointer action is erratic, check the speedometer head for possible binding. The speedometer drive pinion should also be checked. If the pinion is dry or its teeth are stripped, the speedometer may not register properly. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation > Page 4688 Speedometer Head: Service and Repair The following material covers only that service on speedometers which is feasible to perform. Repairs on the units themselves are not included as they require special tools and extreme care when making repairs and adjustments that only an experienced speedometer mechanic should attempt. The speedometer has two main parts, the speedometer head and the speedometer drive cable. When the speedometer fails to indicate speed or mileage, the cable or cable housing is probably broken. SPEEDOMETER CABLE Most cables are broken due to lack of lubrication, or a sharp bend or kink in the housing. A cable might break because of the speedometer head mechanism binds. In such cases, the speedometer head should be repaired or replaced before a new cable or housing is installed. A "jumpy" pointer condition, together with a scraping noise, is due, in most instances, to a dry or kinked speedometer cable. The kinked cable rubs on the housing and winds up, slowing down the pointer. The cable then unwinds and the pointer "jumps." To check for kinks, remove the cable, lay it on a flat surface and twist one end with the fingers. If it turns over smoothly the cable is not kinked. But if part of the cable flops over as it is twisted, the cable is kinked and should be replaced. LUBRICATION The speedometer cable should be lubricated with special cable lubricant. Fill the ferrule on the upper end of the housing with the cable lubricant. Insert the cable in the housing, starting at the upper end. Turn the cable around carefully while feeding it into the housing. Repeat filling the ferrule except for the last six inches of cable. Too much lubricant at this point may cause the lubricant to work into the speedometer head. INSTALLING CABLE During installation, if the cable sticks when inserted in the housing and will not go through, the housing is damaged inside or kinked. Be sure to check the housing from one end to the other. Straighten any sharp bends by relocating clamps or elbows. Replace housing if it is badly kinked or broken. Position the cable and housing so that they lead into the head as straight as possible. Check the new cable for kinks before installing it. Use wide, sweeping, gradual curves where the cable comes out of the transmission and connects to the head so the cable will not be damaged during installation. Arrange the housing so it does not lean against the engine because heat from the engine may dry out the lubricant. If inspection indicates that the cable and housing are in good condition, yet pointer action is erratic, check the speedometer head for possible binding. The speedometer drive pinion should also be checked. If the pinion is dry or its teeth are stripped, the speedometer may not register properly. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Locations Temperature Sensor (Gauge): Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Indicator - A/T > Component Information > Testing and Inspection Temperature Warning Indicator - A/T: Testing and Inspection Fig. 3 Recreational vehicle sensor package instrument cluster. 1980 Fig. 4 Recreational vehicle sensor package instrument cluster. 1981-82 The recreational vehicle sensor package consists of a separate instrument cluster, Figs. 3 and 4, which allows the driver to monitor the following conditions: engine oil level, engine coolant level, transmission fluid level and transmission fluid temperature. TROUBLESHOOTING VOLTAGE LIMITER TEST 1. Connect voltmeter between temperature sending unit (locating in fitting in bottom radiator tank) and a suitable ground. Do not disconnect electrical connector from sending unit. 2. Turn ignition switch to On position and observe voltmeter. 3. If voltmeter needle fluctuates, the voltage limiter is operating properly. 4. If voltmeter does not fluctuate, replace voltage limiter. The voltage limiter is located on the sensor panel. To gain access to the limiter, remove panel and unsnap the back cover. TEMPERATURE GAUGE TEST 1. Disconnect electrical connector from temperature sending unit in lower radiator tank. 2. Connect tester No. C-3826 or equivalent between temperature sending unit and a suitable ground. 3. Move tester pointer to ``C'' position, then turn ignition switch On and observe temperature gauge. Temperature gauge should read within 1/8 inch of ``C''. 4. Move tester pointer to ``M'' position. Temperature gauge should now advance to normal range left of 1/2 position on dial. 5. Move tester pointer to ``H'' position. Temperature gauge should now advance to ``H'' position on dial. 6. If temperature gauge responds to tests described in steps 3, 4 and 5, but does not operate when sending unit electrical connector is attached, the sending unit is defective and should be replaced. 7. If temperature gauge does not respond to tests described in steps 3, 4 and 5, check for loose connections, broken wire, open printed circuit or faulty gauge. OIL LEVEL PUSH BUTTON SWITCH 1. Inspect switch for poor solder connections and repair or replace as necessary. 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the switch should be replaced. To replace switch, Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Indicator - A/T > Component Information > Testing and Inspection > Page 4695 remove circuit board and push switch toward back of sensor housing. PRINTED CIRCUIT BOARD 1. Inspect conductors for cracks or damaged circuits. 2. Test each circuit for continuity using an ohmmeter or test lamp. If any open circuits are found, the sensor panel assembly should be replaced. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation Temperature Warning Lamp/Indicator: Description and Operation A bimetal temperature switch located in the cylinder head controls the operation of a temperature indicator light with a red lens. If the engine cooling system is not functioning properly and coolant temperature exceeds a predetermined value, the warning light will illuminate. TROUBLESHOOTING If the red light is not lit when the engine is being cranked, check for a burned out bulb, an open in the light circuit, or a defective ignition switch. If the red light is lit when the engine is running, check the wiring between light and switch for a ground, defective temperature switch, or overheated cooling system. As a test circuit to check whether the red bulb is functioning properly, a wire which is connected to the ground terminal of the ignition switch is tapped into its circuit. When the ignition is in the "Start" (engine cranking) position, the ground terminal is grounded inside the switch and the red bulb will be lit. When the engine is started and the ignition switch is in the "On" position, the test circuit is opened and the bulb is then controlled by the temperature switch. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation > Page 4699 Temperature Warning Lamp/Indicator: Testing and Inspection A bimetal temperature switch, located in the cylinder head, controls the operation of a temperature indicator light with a red lens. If the engine cooling system is not functioning properly and coolant temperature exceeds a predetermined value, the warning light will illuminate. TROUBLESHOOTING If the red light is not lit when the engine is being cranked, check for a burned out bulb, an open in the light circuit, or a defective ignition switch. If the red light is lit when the engine is running, check the wiring between light and switch for a ground, defective temperature switch, or overheated cooling system. As a test circuit to check whether the red bulb is functioning properly, a wire which is connected to the ground terminal of the ignition switch is tapped into its circuit. When the ignition is in the "Start" (engine cranking) position, the ground terminal is grounded inside the switch and the red bulb will be lit. When the engine is started and the ignition switch is in the "On" position, the test circuit is opened and the bulb is then controlled by the temperature switch. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Vacuum Gauge/Economy Meter > Component Information > Description and Operation Vacuum Gauge/Economy Meter: Description and Operation Fig. 2 Typical vacuum gauge This gauge measures intake manifold vacuum. The intake manifold vacuum varies with engine operating conditions, carburetor adjustments, valve timing, ignition timing and general engine condition. Since the optimum fuel economy is directly proportional to a properly functioning engine, a high vacuum reading on the gauge relates to fuel economy. For this reason some manufacturers call the vacuum gauge a "Fuel Economy Indicator." Most gauges have colored sectors the green sector being the "Economy" range and the red the "Power" range. Therefore, the vehicle should be operated with gauge registering in the green sector or a high numerical number for maximum economy. FUEL ECONOMY WARNING SYSTEM This system actually monitors the engine vacuum just like the vacuum gauge, but all it registers is a low vacuum. The light on the instrument panel warns the vehicle operator when engine manifold vacuum drops below the economical limit. Switch operation is similar to that of the oil pressure indicating light, except that the switch opens when vacuum, rather than oil pressure, is applied. TROUBLESHOOTING Fuel Economy Warning Light The fuel economy warning light should go on when the ignition is turned on. If it does not light, disconnect the wire from the fuel economy vacuum switch connector and ground the wire to the frame or cylinder block. If the warning light still does not go on, check for burned out indicating bulb or an open in the harness between the vacuum switch and instrument panel. If the warning light goes on, circuit is functioning and the vacuum switch should be checked for proper ground. Remove and clean the mounting bracket screws and the mounting surfaces. If system still does not operate, perform the following: With the electrical connector and vacuum tube disconnected from the switch, connect a self-powered test light to the switch electrical connector and to the vacuum gauge mounting bracket. Attach a vacuum pump to gauge (Rotunda Model No. ZRE-10662 hand operated). If the following conditions are not met the switch has to be replaced: 1. With vacuum applied test light should be "Off". 2. With no vacuum to the vacuum switch test light should be "On". 3. If the warning light remains lit when it normally should be out, check vacuum hose to vacuum switch for damage or plugged condition. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Vacuum Gauge/Economy Meter > Component Information > Description and Operation > Page 4703 Vacuum Gauge/Economy Meter: Testing and Inspection Fig. 2 Typical vacuum gauge This gauge measures intake manifold vacuum. The intake manifold vacuum varies with engine operating conditions, carburetor adjustments, valve timing, ignition timing and general engine condition. Since the optimum fuel economy is directly proportional to a properly functioning engine, a high vacuum reading on the gauge relates to fuel economy. For this reason some manufacturers call the vacuum gauge a "Fuel Economy Indicator." Most gauges have colored sectors the green sector being the "Economy" range and the red the "Power" range. Therefore, the vehicle should be operated with gauge registering in the green sector or a high numerical number for maximum economy. FUEL ECONOMY WARNING SYSTEM This system actually monitors the engine vacuum just like the vacuum gauge, but all it registers is a low vacuum. The light on the instrument panel warns the vehicle operator when engine manifold vacuum drops below the economical limit. Switch operation is similar to that of the oil pressure indicating light, except that the switch opens when vacuum, rather than oil pressure, is applied. TROUBLESHOOTING Fuel Economy Warning Light The fuel economy warning light should go on when the ignition is turned on. If it does not light, disconnect the wire from the fuel economy vacuum switch connector and ground the wire to the frame or cylinder block. If the warning light still does not go on, check for burned out indicating bulb or an open in the harness between the vacuum switch and instrument panel. If the warning light goes on, circuit is functioning and the vacuum switch should be checked for proper ground. Remove and clean the mounting bracket screws and the mounting surfaces. If system still does not operate, perform the following: With the electrical connector and vacuum tube disconnected from the switch, connect a self-powered test light to the switch electrical connector and to the vacuum gauge mounting bracket. Attach a vacuum pump to gauge (Rotunda Model No. ZRE-10662 hand operated). If the following conditions are not met the switch has to be replaced: 1. With vacuum applied test light should be "Off". 2. With no vacuum to the vacuum switch test light should be "On". 3. If the warning light remains lit when it normally should be out, check vacuum hose to vacuum switch for damage or plugged condition. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation Volt Meter Gauge: Description and Operation The voltmeter is a gauge which measures the electrical flow from the battery to indicate whether the battery output is within tolerances. The voltmeter reading can range from 13.5-14.0 volts under normal operating conditions. If an undercharge or overcharge condition is indicated for an extended period, the battery and charging system should be checked. TROUBLESHOOTING To check voltmeter, turn key and headlights on with engine off. Pointer should move to 12.5 volts. If no needle movement is observed, check connections from battery to circuit breaker. If connections are tight and meter shows no movement, check wire continuity. If wire continuity is satisfactory, the meter is inoperative and must be replaced. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation > Page 4707 Volt Meter Gauge: Testing and Inspection The voltmeter is a gauge which measures the electrical flow from the battery to indicate whether the battery output is within tolerances. The voltmeter reading can range from 13.5-14.0 volts under normal operating conditions. If an undercharge or overcharge condition is indicated for an extended period, the battery and charging system should be checked. TROUBLESHOOTING To check voltmeter, turn key and headlights on with engine off. Pointer should move to 12.5 volts. If no needle movement is observed, check connections from battery to circuit breaker. If connections are tight and meter shows no movement, check wire continuity. If wire continuity is satisfactory, the meter is inoperative and must be replaced. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Back-Up Light <--> [Backup Lamp] > Backup Lamp Switch > Component Information > Service and Repair Backup Lamp Switch: Service and Repair 1. Unscrew switch from transmission case, allowing fluid to drain into container. 2. Move shift lever to Park and then to Neutral positions and inspect to ensure switch operating lever is centered in switch opening in case. 3. Screw switch into transmission case, then add fluid to the proper level. 4. Check to ensure proper switch operation. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Locations Stop Lamp Switch: Locations On Brake Pedal Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions Stop Lamp Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 4718 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 4719 Stop Lamp Switch: Electrical Diagrams Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 1 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 4720 Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 2 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 4721 Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 3 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Page 4722 Stop Lamp Switch: Service and Repair EXC. MOTOR HOME 1. Disconnect battery ground cable. 2. Disconnect wiring from switch and remove switch from brake pedal bracket. 3. Reverse procedure to install. 4. To adjust, proceed as follows: a. Loosen switch assembly to pedal bracket attaching screw and slide assembly away from pedal blade or striker plate. b. Push brake pedal down and allow to return to free position. Do not pull brake pedal back at any time. c. Place spacer gauge on pedal blade. Models with speed control use a .070 inch spacer, 1980-83 models less speed control use a .130 inch spacer and 1984-87 models less speed control use a .140 inch spacer. d. Slide switch assembly toward pedal blade until switch plunger is fully depressed against spacer gauge without moving the pedal. e. Tighten the switch bracket attaching screw and remove spacer. Ensure stop light switch does not prevent full pedal return. MOTOR HOME 1. Disconnect battery ground cable. 2. Disconnect wiring from switch and remove switch from bracket. 3. Reverse procedure to install. 4. To adjust, proceed as follows: a. Loosen switch locknut, then the switch until plunger is no longer in contact with pedal blade. b. Disconnect pedal return spring and loosen pushrod locknut. c. Remove pushrod end bolt and pedal return spring bracket assembly. d. Position a .010-.015 inch spacer between pedal blade and pedal stop. e. Turn pushrod in or out until pushrod end bolt can be inserted through pedal blade. Ensure pushrod operates smoothly. f. Install pedal return spring bracket and torque attaching nut to 30 ft. lbs. Torque pushrod locknut to 120 inch lbs. g. Remove spacer and connect pedal return spring, then tighten stop light switch until it contacts pedal blade. Continue to tighten switch 2-1/2 complete turns. h. Tighten switch locknut and ensure proper switch operation. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions Cargo Lamp: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4727 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4728 Cargo Lamp: Electrical Diagrams Fig. 6 Ash Tray Lamp, Cigar Lighter & Glove Box Lamp Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4729 Fig. 8 Cargo, Dome & Map Lamps Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions Clearance Lamp: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4734 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4735 Clearance Lamp: Electrical Diagrams Fig. 11 Clearance & Identification Lamps (Roof) 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Clearance Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4736 Fig. 10 Clearance & Identification Lamps (Dual Rear Wheels) 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions Ash Tray Lamp: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4742 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4743 Fig. 6 Ash Tray Lamp, Cigar Lighter & Glove Box Lamp Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions Glove Box Lamp: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4748 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4749 Fig. 6 Ash Tray Lamp, Cigar Lighter & Glove Box Lamp Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions Interior Light Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4754 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4755 Fig. 8 Cargo, Dome & Map Lamps Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions Dome Lamp: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4760 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4761 Fig. 8 Cargo, Dome & Map Lamps Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4766 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4767 Fig. 8 Cargo, Dome & Map Lamps Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Flasher: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 4773 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 4774 Hazard Warning Flasher: Electrical Diagrams Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 1 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 4775 Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 2 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Diagram Information and Instructions > Page 4776 Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 3 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4781 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4782 Hazard Warning Switch: Electrical Diagrams Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 1 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4783 Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 2 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4784 Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 3 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 4785 Hazard Warning Switch: Service and Repair Turn signal switch retainer removal. Standard columns Lock plate retaining ring removal Turn signal switch removal. Tilt columns Taping turn signal connector and wires 1. Disconnect battery ground cable. 2. On 1983-87 models, remove lower bezel from instrument panel. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 4786 3. On all models, remove horn sounder and steering wheel. Refer to ``Horn Sounder & Steering Wheel, Replace'' procedure. 4. On standard columns proceed as follows: a. Remove turn signal lever to switch attaching screw, then the lever. If equipped with speed control, allow lever to hang free. b. Remove switch retainer attaching screws, then the retainer. 5. On tilt columns, proceed as follows: a. Remove plastic cover from lock plate, if equipped. b. Depress lock plate using tool C-4156 or equivalent, then pry retaining ring out of groove using screwdriver. The full load of the cancelling cam spring should not be relieved. If full load is relieved, retaining ring will turn too easily, making removal more difficult. c. Remove lock plate, cancelling cam and spring, then place turn signal lever in right turn position. d. Remove turn signal lever to switch attaching screw, then the lever.If equipped with speed control, allow lever to hang free. e. Remove hazard warning switch knob attaching screw, then the turn signal switch attaching screws. 6. On tilt columns, position steering wheel in midpoint position. 7. On models equipped with column shift, place selector lever in first or third gear position. 8. On all models, remove wire cover attaching clips, then the cover if equipped. 9. Disconnect turn signal electrical connector. Wrap a piece of tape around the connector and wire to prevent snagging during switch removal. 10. Remove turn signal/hazard warning switch assembly by pulling switch up from column while straightening and guiding wires up through column opening. 11. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions Headlight Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 4792 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 4793 Headlight Switch: Electrical Diagrams Fig. 17 Headlamp Switch & Controlled Interior Lighting Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 4794 Fig. 17 Headlamp Switch & Controlled Interior Lighting Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 4795 Headlight Switch: Service and Repair 1981 TRAIL DUSTER & 1981-87 RAMCHARGER & CONVENTIONAL CABS 1. Disconnect battery ground cable, then remove cluster face plate. 2. Depress knob and stem release button located on bottom of switch housing, and pull knob and stem assembly from switch. 3. Remove wiper switch knob, then the bezel. 4. Remove switch attaching nut, then disconnect switch electrical connector and remove switch. 5. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair LUXURY TYPE PADDED STEERING WHEEL 1. Disconnect battery ground cable. 2. Pry off pad, then disconnect electrical connector from horn ring terminal. 3. Remove each horn switch to steering wheel retaining screw and lift out horn button switches from wheel. 4. Remove steering wheel nut, then the wheel using a suitable puller. Do not bump or hammer on steering shaft to remove wheel, as damage to shaft may result. 5. Reverse procedure to install. PADDED TYPE EXC. LUXURY TYPE STEERING WHEEL 1. Disconnect battery ground cable. 2. On models with horn pad mounting screws located behind steering wheel spokes, remove screws and the pad. On all other models equipped with horn pad, pry horn pad from wheel. 3. Disconnect horn switch electrical connector. 4. Remove horn switch to retainer attaching screws, then the switch from retainer. 5. Remove steering wheel nut, then the steering wheel using a suitable puller. Do not bump or hammer on steering shaft to remove wheel, as damage to shaft may result. 6. Reverse procedure to install. SPORT STEERING WHEEL 1. Disconnect battery ground cable. 2. Lift horn button off wheel, then disconnect switch electrical connector. 3. Remove steering wheel nut. 4. Remove horn switch to steering wheel attaching screw, then the horn switch. 5. Remove steering wheel using suitable puller. Do not bump or hammer on steering shaft to remove wheel, as damage to shaft may result. 6. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Component Information > Technical Service Bulletins > Customer Interest for Map Light: > 080589 > Feb > 89 > Map Lamp - Tabs Broken Map Light: Customer Interest Map Lamp - Tabs Broken Models 1982-1989 Domestic D/AD & W model Trucks & Sport Utility Vehicles Subject Map Lamp Tab Breakage Index ELECTRICAL Date February 20, 1989 No. 08-05-89 P-617 (C08-04-9) FIGURE 1 This Technical Service Bulletin is being revised to include 1988 and 1989 model years. BODY CODE LEGEND 1982-1988 D & W - Dodge Ram Pickup/Ramcharger Sport Utility 1989 AD - Dodge Ram Pickup/Ramcharger Sport Utility SYMPTOM/CONDITION Broken map lamp mounting tabs for the under dash mounted map lamp. PARTS REQUIRED Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Component Information > Technical Service Bulletins > Customer Interest for Map Light: > 080589 > Feb > 89 > Map Lamp - Tabs Broken > Page 4808 Lamp Mounting Bracket Repair Package, P/N 4439009 REPAIR PROCEDURE This repair involves the installation of a map lamp retaining bracket. Remove the instrument bezel in accordance with service manual procedures. Locate the repair bracket, PN 4439009, over the broken lamp mounting tabs on the instrument panel bezel. The repair bracket should be positioned so that it will be retained by the instrument panel bezel retaining screws (Figure 1A). Carefully reinstall the instrument panel bezel, making sure the replacement bracket does not come out of position. Secure the bezel and bracket with the bezel mounting screws. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 23-11-16-91 . . . . . . . . . . . 0.4 Hrs. FAILURE CODE: 11 - Broken or Cracked Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Map Light: > 080589 > Feb > 89 > Map Lamp - Tabs Broken Map Light: All Technical Service Bulletins Map Lamp - Tabs Broken Models 1982-1989 Domestic D/AD & W model Trucks & Sport Utility Vehicles Subject Map Lamp Tab Breakage Index ELECTRICAL Date February 20, 1989 No. 08-05-89 P-617 (C08-04-9) FIGURE 1 This Technical Service Bulletin is being revised to include 1988 and 1989 model years. BODY CODE LEGEND 1982-1988 D & W - Dodge Ram Pickup/Ramcharger Sport Utility 1989 AD - Dodge Ram Pickup/Ramcharger Sport Utility SYMPTOM/CONDITION Broken map lamp mounting tabs for the under dash mounted map lamp. PARTS REQUIRED Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Map Light: > 080589 > Feb > 89 > Map Lamp - Tabs Broken > Page 4814 Lamp Mounting Bracket Repair Package, P/N 4439009 REPAIR PROCEDURE This repair involves the installation of a map lamp retaining bracket. Remove the instrument bezel in accordance with service manual procedures. Locate the repair bracket, PN 4439009, over the broken lamp mounting tabs on the instrument panel bezel. The repair bracket should be positioned so that it will be retained by the instrument panel bezel retaining screws (Figure 1A). Carefully reinstall the instrument panel bezel, making sure the replacement bracket does not come out of position. Secure the bezel and bracket with the bezel mounting screws. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 23-11-16-91 . . . . . . . . . . . 0.4 Hrs. FAILURE CODE: 11 - Broken or Cracked Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions Map Light: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 4817 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams > Diagram Information and Instructions > Page 4818 Fig. 8 Cargo, Dome & Map Lamps Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions Marker Lamp: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4823 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4824 Marker Lamp: Electrical Diagrams Fig. 10 Clearance & Identification Lamps (Dual Rear Wheels) 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4825 Fig. 11 Clearance & Identification Lamps (Roof) 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Service and Repair Backup Lamp Switch: Service and Repair 1. Unscrew switch from transmission case, allowing fluid to drain into container. 2. Move shift lever to Park and then to Neutral positions and inspect to ensure switch operating lever is centered in switch opening in case. 3. Screw switch into transmission case, then add fluid to the proper level. 4. Check to ensure proper switch operation. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Locations Stop Lamp Switch: Locations On Brake Pedal Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions Stop Lamp Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 4835 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 4836 Stop Lamp Switch: Electrical Diagrams Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 1 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 4837 Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 2 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 4838 Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 3 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Stop Lamp Switch <--> [Brake Light Switch] > Component Information > Diagrams > Page 4839 Stop Lamp Switch: Service and Repair EXC. MOTOR HOME 1. Disconnect battery ground cable. 2. Disconnect wiring from switch and remove switch from brake pedal bracket. 3. Reverse procedure to install. 4. To adjust, proceed as follows: a. Loosen switch assembly to pedal bracket attaching screw and slide assembly away from pedal blade or striker plate. b. Push brake pedal down and allow to return to free position. Do not pull brake pedal back at any time. c. Place spacer gauge on pedal blade. Models with speed control use a .070 inch spacer, 1980-83 models less speed control use a .130 inch spacer and 1984-87 models less speed control use a .140 inch spacer. d. Slide switch assembly toward pedal blade until switch plunger is fully depressed against spacer gauge without moving the pedal. e. Tighten the switch bracket attaching screw and remove spacer. Ensure stop light switch does not prevent full pedal return. MOTOR HOME 1. Disconnect battery ground cable. 2. Disconnect wiring from switch and remove switch from bracket. 3. Reverse procedure to install. 4. To adjust, proceed as follows: a. Loosen switch locknut, then the switch until plunger is no longer in contact with pedal blade. b. Disconnect pedal return spring and loosen pushrod locknut. c. Remove pushrod end bolt and pedal return spring bracket assembly. d. Position a .010-.015 inch spacer between pedal blade and pedal stop. e. Turn pushrod in or out until pushrod end bolt can be inserted through pedal blade. Ensure pushrod operates smoothly. f. Install pedal return spring bracket and torque attaching nut to 30 ft. lbs. Torque pushrod locknut to 120 inch lbs. g. Remove spacer and connect pedal return spring, then tighten stop light switch until it contacts pedal blade. Continue to tighten switch 2-1/2 complete turns. h. Tighten switch locknut and ensure proper switch operation. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4844 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4845 Fig. 8 Cargo, Dome & Map Lamps Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4850 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4851 Hazard Warning Switch: Electrical Diagrams Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 1 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4852 Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 2 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4853 Fig. 16 Hazard, Stop & Turn Lamps Wiring Circuit (Part 3 of 3). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 4854 Hazard Warning Switch: Service and Repair Turn signal switch retainer removal. Standard columns Lock plate retaining ring removal Turn signal switch removal. Tilt columns Taping turn signal connector and wires 1. Disconnect battery ground cable. 2. On 1983-87 models, remove lower bezel from instrument panel. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 4855 3. On all models, remove horn sounder and steering wheel. Refer to ``Horn Sounder & Steering Wheel, Replace'' procedure. 4. On standard columns proceed as follows: a. Remove turn signal lever to switch attaching screw, then the lever. If equipped with speed control, allow lever to hang free. b. Remove switch retainer attaching screws, then the retainer. 5. On tilt columns, proceed as follows: a. Remove plastic cover from lock plate, if equipped. b. Depress lock plate using tool C-4156 or equivalent, then pry retaining ring out of groove using screwdriver. The full load of the cancelling cam spring should not be relieved. If full load is relieved, retaining ring will turn too easily, making removal more difficult. c. Remove lock plate, cancelling cam and spring, then place turn signal lever in right turn position. d. Remove turn signal lever to switch attaching screw, then the lever.If equipped with speed control, allow lever to hang free. e. Remove hazard warning switch knob attaching screw, then the turn signal switch attaching screws. 6. On tilt columns, position steering wheel in midpoint position. 7. On models equipped with column shift, place selector lever in first or third gear position. 8. On all models, remove wire cover attaching clips, then the cover if equipped. 9. Disconnect turn signal electrical connector. Wrap a piece of tape around the connector and wire to prevent snagging during switch removal. 10. Remove turn signal/hazard warning switch assembly by pulling switch up from column while straightening and guiding wires up through column opening. 11. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions Headlight Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 4860 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 4861 Headlight Switch: Electrical Diagrams Fig. 17 Headlamp Switch & Controlled Interior Lighting Wiring Circuit (Part 1 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 4862 Fig. 17 Headlamp Switch & Controlled Interior Lighting Wiring Circuit (Part 2 of 2). 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Diagrams > Page 4863 Headlight Switch: Service and Repair 1981 TRAIL DUSTER & 1981-87 RAMCHARGER & CONVENTIONAL CABS 1. Disconnect battery ground cable, then remove cluster face plate. 2. Depress knob and stem release button located on bottom of switch housing, and pull knob and stem assembly from switch. 3. Remove wiper switch knob, then the bezel. 4. Remove switch attaching nut, then disconnect switch electrical connector and remove switch. 5. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair LUXURY TYPE PADDED STEERING WHEEL 1. Disconnect battery ground cable. 2. Pry off pad, then disconnect electrical connector from horn ring terminal. 3. Remove each horn switch to steering wheel retaining screw and lift out horn button switches from wheel. 4. Remove steering wheel nut, then the wheel using a suitable puller. Do not bump or hammer on steering shaft to remove wheel, as damage to shaft may result. 5. Reverse procedure to install. PADDED TYPE EXC. LUXURY TYPE STEERING WHEEL 1. Disconnect battery ground cable. 2. On models with horn pad mounting screws located behind steering wheel spokes, remove screws and the pad. On all other models equipped with horn pad, pry horn pad from wheel. 3. Disconnect horn switch electrical connector. 4. Remove horn switch to retainer attaching screws, then the switch from retainer. 5. Remove steering wheel nut, then the steering wheel using a suitable puller. Do not bump or hammer on steering shaft to remove wheel, as damage to shaft may result. 6. Reverse procedure to install. SPORT STEERING WHEEL 1. Disconnect battery ground cable. 2. Lift horn button off wheel, then disconnect switch electrical connector. 3. Remove steering wheel nut. 4. Remove horn switch to steering wheel attaching screw, then the horn switch. 5. Remove steering wheel using suitable puller. Do not bump or hammer on steering shaft to remove wheel, as damage to shaft may result. 6. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions Interior Light Switch: Diagram Information and Instructions Symbol Identification How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4871 Main Circuit ID Codes Wire Color Code Identification Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 4872 Fig. 8 Cargo, Dome & Map Lamps Wiring Circuit. 1985 Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair Turn Signal Switch: Service and Repair Turn Signal/Hazard Warning Switch Turn signal switch retainer removal. Standard columns Lock plate retaining ring removal Turn signal switch removal. Tilt columns Taping turn signal connector and wires 1. Disconnect battery ground cable. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Page 4876 2. On 1983-87 models, remove lower bezel from instrument panel. 3. On all models, remove horn sounder and steering wheel. Refer to ``Horn Sounder & Steering Wheel, Replace'' procedure. 4. On standard columns proceed as follows: a. Remove turn signal lever to switch attaching screw, then the lever. If equipped with speed control, allow lever to hang free. b. Remove switch retainer attaching screws, then the retainer. 5. On tilt columns, proceed as follows: a. Remove plastic cover from lock plate, if equipped. b. Depress lock plate using tool C-4156 or equivalent, then pry retaining ring out of groove using screwdriver. The full load of the cancelling cam spring should not be relieved. If full load is relieved, retaining ring will turn too easily, making removal more difficult. c. Remove lock plate, cancelling cam and spring, then place turn signal lever in right turn position. d. Remove turn signal lever to switch attaching screw, then the lever.If equipped with speed control, allow lever to hang free. e. Remove hazard warning switch knob attaching screw, then the turn signal switch attaching screws. 6. On tilt columns, position steering wheel in midpoint position. 7. On models equipped with column shift, place selector lever in first or third gear position. 8. On all models, remove wire cover attaching clips, then the cover if equipped. 9. Disconnect turn signal electrical connector. Wrap a piece of tape around the connector and wire to prevent snagging during switch removal. 10. Remove turn signal/hazard warning switch assembly by pulling switch up from column while straightening and guiding wires up through column opening. 11. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair Turn Signal Switch: Service and Repair Turn Signal/Hazard Warning Switch Turn signal switch retainer removal. Standard columns Lock plate retaining ring removal Turn signal switch removal. Tilt columns Taping turn signal connector and wires 1. Disconnect battery ground cable. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair > Page 4881 2. On 1983-87 models, remove lower bezel from instrument panel. 3. On all models, remove horn sounder and steering wheel. Refer to ``Horn Sounder & Steering Wheel, Replace'' procedure. 4. On standard columns proceed as follows: a. Remove turn signal lever to switch attaching screw, then the lever. If equipped with speed control, allow lever to hang free. b. Remove switch retainer attaching screws, then the retainer. 5. On tilt columns, proceed as follows: a. Remove plastic cover from lock plate, if equipped. b. Depress lock plate using tool C-4156 or equivalent, then pry retaining ring out of groove using screwdriver. The full load of the cancelling cam spring should not be relieved. If full load is relieved, retaining ring will turn too easily, making removal more difficult. c. Remove lock plate, cancelling cam and spring, then place turn signal lever in right turn position. d. Remove turn signal lever to switch attaching screw, then the lever.If equipped with speed control, allow lever to hang free. e. Remove hazard warning switch knob attaching screw, then the turn signal switch attaching screws. 6. On tilt columns, position steering wheel in midpoint position. 7. On models equipped with column shift, place selector lever in first or third gear position. 8. On all models, remove wire cover attaching clips, then the cover if equipped. 9. Disconnect turn signal electrical connector. Wrap a piece of tape around the connector and wire to prevent snagging during switch removal. 10. Remove turn signal/hazard warning switch assembly by pulling switch up from column while straightening and guiding wires up through column opening. 11. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Power Window Relay: Locations Door Lock And Power Window Circuit Breaker And Relays Location The relay is located behind the dash panel, to the left of the glove box. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 4887 Power Window Relay: Testing and Inspection Locate the window lift relay and test as follows: 1. Check for a constant power source at the LG wire. ^ If power is present, go to step 2. ^ If power is not present, check the circuit breaker and connecting wires. 2. Check for ground at the WT wire. ^ If a ground is present, go to step 3. ^ If a good ground is not present, check for an open in the WT wire to ground. 3. Check for a power source at the DB wire when the key is turned to the "run" position. ^ If power is present, go to step 4. ^ If power is not present, check for an open in the DB wire from the ignition switch or a defective ignition feed fuse. 4. Check for power at the TN wire. ^ If power is present, the relay is operating properly. ^ If power is not present, replace the relay. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 4888 Power Window Relay: Service and Repair Door Lock And Power Window Circuit Breaker And Relays Location Disconnect the battery negative terminal. Remove the wire connector from the relay. Remove the attaching bolt that holds the relay to the instrument panel. Install by attaching relay to the instrument panel and connecting the wires to the relay. Connect the battery negative terminal and test the system for proper operation. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations Door Components The power window switch is located near the top of each door panel. The master switch on the drivers door can also control the other door(s). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 4893 Power Window Switch: Testing and Inspection Window Switch Connector 1. Remove the left power window switch from the trim panel and remove the wiring harness from the back of the switch. Connect jumper wires as shown to the left switch harness forcing the windows to operate in each direction. ^ If the window motors operate properly, the left switch is defective. ^ If the left window motor does not operate properly, the window motor or wiring may be defective. ^ If the right window motor does not operate properly, go to step 2. 2. Remove the right power window switch from the trim panel and remove the wiring harness from the back of the switch. Connect the jumper wires to the right switch harness as shown and test using jumper wires at the left door harness. ^ If the right window motor operates properly, the right window switch is defective. ^ If the right window motor does not operate properly, the right window motor or wiring may be defective. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 4894 Power Window Switch: Service and Repair Door Components Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 4895 Power Window Switch Replacement Disconnect the battery negative terminal. Using a small flat blade screwdriver, carefully pry the power window switch from the door panel bezel. Remove the wire connector from the power window switch by carefully prying between the connector and the back of the switch. Install by pressing the wire connector onto the switch and pressing the switch into the door panel bezel. Connect the battery negative terminal and test the system for proper operation. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Specifications Power Window Circuit Breaker: Specifications Power Window Circuit Breaker Specification ..................................................................................................................................................... 30 amps Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Specifications > Page 4900 Power Window Circuit Breaker: Locations Door Lock And Power Window Circuit Breaker And Relays Location The circuit breaker is located behind the dash panel, in cavity # 10 of the fuse block. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Specifications > Page 4901 Power Window Circuit Breaker: Testing and Inspection Door Lock And Power Window Circuit Breaker And Relays Location To test the circuit breaker, connect the negative lead of a voltmeter to a known good ground, and touch the positive lead to one terminal of the circuit breaker. If battery voltage is present, test the other terminal of the circuit breaker. If battery voltage is present on only one terminal, then the circuit breaker is defective. If battery voltage is present on neither terminal, check for a burned fusible link or power lead wire to the circuit breaker. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Specifications > Page 4902 Power Window Circuit Breaker: Service and Repair Door Lock And Power Window Circuit Breaker And Relays Location Remove the four screws that attach the lower steering column cover to the dash panel. Locate the circuit breaker in cavity # 10 and pull it out. Use a test light check for power in cavity # 10. Power should be present only on one terminal. Install the new circuit breaker by pushing it in slowly, making certain that both terminals hold snugly. Power should now be present at both terminals. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair Power Window Regulator Mounting Removal Remove the trim panel(s) to gain access to the window motor. Disconnect the wire connector from the motor. Remove the rivets that secure the regulator to the inner door panel. Remove the screw that holds the window motor tie down bracket to the inner door panel (if equipped). Manually move the regulator assembly to disengage the regulator slider from the glass lift channel. Secure the window glass in the up position with several straps of duct tape looped over the window frame. Remove the regulator through the door access hole. If window motor needs to be removed from the regulator, secure the regulator in a vise to prevent the sector gear from moving.[1] Remove three motor attaching screws and remove window motor from the regulator. [1] WARNING:If the sector gear is not properly secured to prevent movement, the counter balance spring will cause the regulator arm to move rapidly when the window motor is removed from the regulator. This may cause personal injury. Installation Install window motor to regulator using original mounting screws. Inspect the sector gear teeth and window motor teeth for proper mesh. Remove the regulator assembly from the vise and insert through the door access panel. Manually position the regulator arm slide in the window lift channel. Secure the regulator assembly to the inner door panel using either new rivets or matching nut, bolt, and washer sets. Install screw to motor tie down bracket (if equipped). Connect motor wiring to harness and test system for proper operation. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations Power Window Relay: Locations Door Lock And Power Window Circuit Breaker And Relays Location The relay is located behind the dash panel, to the left of the glove box. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Page 4910 Power Window Relay: Testing and Inspection Locate the window lift relay and test as follows: 1. Check for a constant power source at the LG wire. ^ If power is present, go to step 2. ^ If power is not present, check the circuit breaker and connecting wires. 2. Check for ground at the WT wire. ^ If a ground is present, go to step 3. ^ If a good ground is not present, check for an open in the WT wire to ground. 3. Check for a power source at the DB wire when the key is turned to the "run" position. ^ If power is present, go to step 4. ^ If power is not present, check for an open in the DB wire from the ignition switch or a defective ignition feed fuse. 4. Check for power at the TN wire. ^ If power is present, the relay is operating properly. ^ If power is not present, replace the relay. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Page 4911 Power Window Relay: Service and Repair Door Lock And Power Window Circuit Breaker And Relays Location Disconnect the battery negative terminal. Remove the wire connector from the relay. Remove the attaching bolt that holds the relay to the instrument panel. Install by attaching relay to the instrument panel and connecting the wires to the relay. Connect the battery negative terminal and test the system for proper operation. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations Power Window Switch: Locations Door Components The power window switch is located near the top of each door panel. The master switch on the drivers door can also control the other door(s). Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 4915 Power Window Switch: Testing and Inspection Window Switch Connector 1. Remove the left power window switch from the trim panel and remove the wiring harness from the back of the switch. Connect jumper wires as shown to the left switch harness forcing the windows to operate in each direction. ^ If the window motors operate properly, the left switch is defective. ^ If the left window motor does not operate properly, the window motor or wiring may be defective. ^ If the right window motor does not operate properly, go to step 2. 2. Remove the right power window switch from the trim panel and remove the wiring harness from the back of the switch. Connect the jumper wires to the right switch harness as shown and test using jumper wires at the left door harness. ^ If the right window motor operates properly, the right window switch is defective. ^ If the right window motor does not operate properly, the right window motor or wiring may be defective. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 4916 Power Window Switch: Service and Repair Door Components Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 4917 Power Window Switch Replacement Disconnect the battery negative terminal. Using a small flat blade screwdriver, carefully pry the power window switch from the door panel bezel. Remove the wire connector from the power window switch by carefully prying between the connector and the back of the switch. Install by pressing the wire connector onto the switch and pressing the switch into the door panel bezel. Connect the battery negative terminal and test the system for proper operation. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Locations Window Regulator: Locations Power Window Regulator Mounting The power window motor is attached to the window regulator. This assembly is bolted to the inside door frame panel. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Locations > Page 4921 Window Regulator: Testing and Inspection Power Window Motor/Regulator Test To test an individual window motor, remove the door trim panel(s) to gain access to the window motor. Disconnect the window motor wire connector. Using a test battery, connect a jumper wire between the positive terminal of the battery and one of the window motor terminals. Using a jumper wire, momentarily connect the other window motor terminal to the negative terminal. The motor should now rotate causing the window to go either up or down.[1] Reverseing the battery leads to the opposite terminals should make the window move in the opposite direction. Check for smooth window operation through the entire window travel. If the window does not move, remove the window motor for further testing and/or repairs. If the window does move but not smoothly, check for a binding window track or regulator. Remarks [1] If the window is already in either the full up or full down positions, it will not move any further in that direction. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Locations > Page 4922 Window Regulator: Service and Repair Power Window Regulator Mounting Removal Remove the trim panel(s) to gain access to the window motor. Disconnect the wire connector from the motor. Remove the rivets that secure the regulator to the inner door panel. Remove the screw that holds the window motor tie down bracket to the inner door panel (if equipped). Manually move the regulator assembly to disengage the regulator slider from the glass lift channel. Secure the window glass in the up position with several straps of duct tape looped over the window frame. Remove the regulator through the door access hole. If window motor needs to be removed from the regulator, secure the regulator in a vise to prevent the sector gear from moving.[1] Remove three motor attaching screws and remove window motor from the regulator. [1] WARNING:If the sector gear is not properly secured to prevent movement, the counter balance spring will cause the regulator arm to move rapidly when the window motor is removed from the regulator. This may cause personal injury. Installation Install window motor to regulator using original mounting screws. Inspect the sector gear teeth and window motor teeth for proper mesh. Remove the regulator assembly from the vise and insert through the door access panel. Manually position the regulator arm slide in the window lift channel. Secure the regulator assembly to the inner door panel using either new rivets or matching nut, bolt, and washer sets. Install screw to motor tie down bracket (if equipped). Connect motor wiring to harness and test system for proper operation. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair Wiper Switch: Service and Repair 1981 TRAIL DUSTER & 1981-87 RAMCHARGER & CONVENTIONAL CAB 1. Disconnect battery ground cable, then remove cluster face plate. 2. Depress head light knob and stem release button located on bottom of switch housing and pull knob and stem assembly from switch. 3. Pull wiper switch knob off wiper switch. 4. Remove bezel attaching screws, then the bezel. 5. Remove four wiper switch attaching screws. 6. Disconnect switch electrical connectors, then remove switch. 7. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Customer Interest for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: Customer Interest Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Wiper Transmission <--> [Wiper Gear Box] > Component Information > Service and Repair Windshield Wiper Transmission: Service and Repair Fig. 13 Windshield wiper transmission assembly. 1980-81 Trail Duster & 1980-87 Ramcharger & Conventional Cabs 1980-81 TRAIL DUSTER & 1980-87 RAMCHARGER & CONVENTIONAL CAB Crank Arm, Replace 1. Remove wiper motor. Refer to "Windshield Wiper Motor, Replace" procedure. 2. Remove crank arm to motor drive shaft attaching nut, then the crank arm. 3. Reverse procedure to install. Drive Link & Left Pivot Assembly, Replace 1. Remove wiper arms, then the cowl cover attaching screws and cover. 2. Remove drive link from right pivot by prying retainer bushing apart using a suitable screwdriver. 3. Remove crank arm from drive link by prying retainer bushing from crank arm pin using a suitable screwdriver. 4. Remove left pivot attaching screws and allow pivot to hang free. 5. Remove drive links and left pivot as an assembly. 6. Remove drive link from left pivot by prying retainer bushing from pivot pin using a suitable screwdriver. 7. Reverse procedure to install. Right Pivot Assembly, Replace 1. Remove wiper arms, then the cowl cover attaching screws and cover. 2. Remove drive link from right pivot by prying retainer bushing from pivot pin using suitable screwdriver. 3. Remove right pivot attaching screws, then the pivot through access hole. 4. Reverse procedure to install. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair Wiper Motor: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect wiper motor electrical connectors, then remove motor attaching screws. 3. Lower motor down far enough to gain access to crank arm to drive link retainer bushing. 4. Remove crank arm from drive link by prying retainer bushing from crank arm pin using a suitable screwdriver. 5. Remove motor from vehicle. Dodge D 250 Pickup Workshop Manual (V8-318 5.2L (1985)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair Wiper Switch: Service and Repair 1981 TRAIL DUSTER & 1981-87 RAMCHARGER & CONVENTIONAL CAB 1. Disconnect battery ground cable, then remove cluster face plate. 2. Depress head light knob and stem release button located on bottom of switch housing and pull knob and stem assembly from switch. 3. Pull wiper switch knob off wiper switch. 4. Remove bezel attaching screws, then the bezel. 5. Remove four wiper switch attaching screws. 6. Disconnect switch electrical connectors, then remove switch. 7. Reverse procedure to install.