Dodge - Ram Pick up - Wiring Diagram - 1981 - 1985

Page 1187 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 Page 473 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. Locations Cruise Control Module: Locations Speed Control System Components LH Side Of Engine Compartment Page 986 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). Wheel Cover - Loose/Falls Off Wheels: All Technical Service Bulletins Wheel Cover - Loose/Falls Off Models 1984 D, W & B 250 - 350 Dodge Pick-Up Trucks & Van/Wagons Subject Wheel Cover Retention With 16.5 x 6.75 H.D. Wheels Index WHEELS & TIRES Date November 12, 1984 No. 22-01-84 P-4993-C SYMPTOM/CONDITION A small number of subject vehicles may exhibit a condition of lack of wheel cover/hub cap retension on one or more of the wheels. The wheel covers/hub caps may not grip the embossment on the wheel, thus the cover will not stay on. This occurs primarily during installation at new vehicle pre-delivery. If the above condition occurs, the wheel must be replaced. PARTS REQUIRED 16.5 x 6.75 H.D. Wheel PN 4284446 NOTE: REPLACED WHEELS MUST BE RETURNED TO THE MATERIAL RETURN CENTER. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 22-40-01-02 . . . . . . . . . . . 0.6 Hrs. FAILURE CODE: HR - Improper Retention Page 871 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. Page 1468 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. Page 1185 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 Page 2621 Universal Joint: Service and Repair Cross & Roller Type 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 Page 3826 FIGURE 3-A Page 3180 Fig. 12 Using driving & adapter to install seal cup into knuckle. 44 FBJ Units w/disc brakes. Models w/full time 4WD Fig. 13 Tools in place after seal cup is installed. 44 FBJ Units w/disc brakes. Models w/full time 4WD Fig. 15 Forming a seal on bearing retainer face. 44 FBJ Units w/disc brakes. Models w/full time 4WD Fig. 16 Bearing retainer positioned with grease fitting facing forward. 44 FBJ Units w/disc brakes. Models w/full time 4WD Page 196 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Page 1660 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. Page 9 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. Specifications Page 3476 Fig. 9 Speed control wiring diagram. 1986 rear wheel drive Ram Van & Wagons Adjustments Fig. 2 Transfer case shifter assembly and linkage adjustment. 1984 NP-208 Page 3743 Fig. 37 Oil Lamp With Gauge Cluster Wiring Circuit. 1984 Page 614 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 Page 1480 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Page 2594 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 Page 1663 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 Page 71 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 Page 2945 Battery: Mechanical Specifications Optional Battery Optional Battery BCI Group Number 24 Cranking Performance 500 A Standard Battery Standard Battery BCI Group Number 25 Cranking Performance 370 A 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. Page 3591 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) Page 3057 Fuse: Service and Repair Circuit Breaker/Fuse Replacement Door Lock And Power Window Circuit Breaker And Relays Location Disconnect the battery negative terminal. Remove the two wires from the circuit breaker and remove the circuit breaker from its mounting clip. Install new circuit breaker to the mounting clip and connect the two wires. Connect the battery negative terminal and test power door lock system for proper operation. Specifications Diagram Information and Instructions Intake Air Temperature 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. Page 3862 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. Page 3657 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 Upholstery - Cleaning Procedure Seats: Technical Service Bulletins Upholstery - Cleaning Procedure Models All ChryslerPlymouth & Dodge Vehicles Subject Cloth Seat Cleaning Procedure Index BODY Date February 6, 1989 No. 23-03-89 P-367 (C23-02-9) The following is the recommended procedure for the cleaning of soiled cloth seat upholstery. Use of improper cleaning materials or procedures may result in swelling or deterioration of foam, discoloration of fabric, or loosening the bond between the seat fabric and foam. NOTE: USE ONLY THE APPROVED MOPAR CLEANERS OR EQUIVALENT OR A MILD SOAP SOLUTION. PARTS REQUIRED Super Kleen PN 4318015 or Total Clean PN 4318019 REPAIR PROCEDURE 1. Apply approved cleaner to soiled area with cloth after wringing out excess cleaner. 2. Do not soak upholstery, even with recommended cleaners. 3. Wipe soiled area with a lifting motion. 4. Wipe off immediately with a clean, dry towel or rag. NOTE: DO NOT USE CARPET TYPE CLEANING APPARATUS THAT BLOWS IN SOLVENT OR STEAM, NOR ANY HOUSEHOLD CLEANERS NOT SPECIFICALLY RECOMMENDED FOR CLOTH UPHOLSTERY. POLICY: Information only Page 2554 Axle Shaft: Technical Service Bulletins Differential Gear/Axle Shaft - C Lock Revision Models 1984 Domestic Trucks, Vans & Wagons Equipped With 9-1/4 Rear Axle Subject Revised "C" Lock, Differential Gear & Axle Shaft Index REAR AXLE Date November 5, 1984 No. 03-02-84 P-4912-C FIGURE 1 FIGURE 2 A revised rear axle assembly with larger axle "C" locks entered production on February 12, 1984 (Figure 1). The corresponding axle shafts and differential side gears were changed to accommodate the larger "C" locks. Axle assemblies built with the larger "C" locks and components are identified with the letter "X" stamped as shown in Figure 2. CAUTION: THE LARGER "C" LOCKS AND CORRESPONDING AXLE SHAFTS AND DIFFERENTIAL GEARS MUST NOT BE INTERCHANGED WITH Page 1189 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). 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. Page 981 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. Page 1213 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 Page 2736 Fig. 16 Bearing retainer positioned with grease fitting facing forward. 44 FBJ Units w/disc brakes. Models w/full time 4WD 4. Install seal cup using adapter, Tool C-4398-2, and driver, Tool No. C-4398-1. Use a small amount of wheel bearing grease on adapter face to hold cup in position, then drive up until bottomed in knuckle. Do not remove tool at this time. 5. Using a suitable tool, install new outer seal in retainer plate, then locate retainer plate over hub of rotor. 6. Thoroughly pack wheel bearings with Multi-Purpose grease and press outer bearing onto hub using Tool No. C-4246-A and adapters. Remove tool and place grease coated outer bearing cup over bearing cone followed by spacer, grease coated inner bearing cup and inner bearing cone. Again use Tool No. C-4246-A and adapters to press components into position. Remove tool. 7. Apply a 1/4 inch bead of RTV sealer to retainer face on the chamfer. This replaces O-ring discarded during disassembly. 8. Carefully remove seal installing tool from knuckle bore so that outer axle shaft remains centered. If shaft is moved, be sure that lip seal is still riding inside cup. Correct if necessary. 9. Before assembling hub and rotor to knuckle, position bearing retainer in hub so that grease fitting is facing forward, if equipped. Using a crossing method, torque retainer plate bolts to 30 ft-lbs. Bearing retainers that have a grease fitting must be positioned on knuckle so that fitting is facing directly forward. 10. Install brake adapter and remove pry bar from universal joint. 11. Install axle shaft washer and nut. Torque nut to 100 ft-lbs, and continue to tighten nut until next slot in nut aligns with hole in axle shaft. Install cotter pin. 12. Through the access hole in hub, lubricate fitting in bearing retainer with multipurpose grease until grease flows through new inner seal. Seal may be viewed at the universal joint area. Spin hub several times and lubricate fitting again. Grease must flow from 1/2 of seal diameter. 13. Replace brake caliper assembly and wheel, then lower truck and test operation. With Part Time 4WD Differentials Fluid - Differential: Specifications Differentials Above 90°F (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....................................................... ..........................................................................................................................................................G L-5 CAPACITY, Refill: Front: 4-wheel drive Spicer 60F....................................................................... ....................................................................................3.1 Liters 6.5 Pints Others................................................................................................................................................... ...............................................1.7 Liters 3.5 Pints Rear: Spicer 60, 60 HD........................................................................................................................ ................................................2.8 Liters 6.0 Pints Spicer 70.............................................................................................................................................. ................................................3.1 Liters 6.5 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 the ground, turn one wheel & other will rotate in same direction 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. Page 3426 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 support bracket. Install by attaching relay to the instrument panel support bracket and connecting the wires to the relay. Connect the battery negative terminal and test the system for proper operation. Page 989 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. Page 2732 Outer Locknut, Lockwasher And Inner Locknut Fig 1 Disc Brake Assembly (Rear View) Electronic Control Unit Engine Control Module: Locations Electronic Control Unit Electronic Ignition System Components On Firewall 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 Page 353 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. Page 2091 FIGURE 3C - BODY WIRING Page 2599 5. Lubricate splines with automatic transmission fluid. 6. Reinstall driveshaft. 7. Lower vehicle and road test. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 16-30-10-01................................ 0.6 Hrs. Refer to Labor Operation Time Schedule FAILURE CODE: 52 - Improperly Machined Page 1640 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. Page 3787 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 Page 38 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. Page 3810 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. Page 179 (zero resistance) in the other lock knob position. If the door switch does not test properly, it is defective. Page 3136 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. Page 3122 Steering Column: Service and Repair Without Tilt Removal/Installation Fig. 1 Steering column installation. Motor Home MOTOR HOME Removal 1. Disconnect battery ground cable. 2. Remove pot coupling to steering gear shaft clamp nut and bolt. 3. Disconnect electrical connector at column jacket. 4. Remove horn and pad assembly, then remove steering wheel using a suitable puller. Do not attempt to remove steering wheel using a hammer as damage to the steering column and shaft will result. 5. Remove the 4 boot floor plate retaining bolts. 6. Remove the two column clamp to tilt assembly screws and remove column. Installation 1. Place floor plate and boot on column, then slide column assembly through floor pan opening. 2. Position column so that steering shaft bearing blocks are centered in the pot coupling, then torque the clamp bolt to 35 ft lb. 3. Install but do not tighten steering column upper bracket bolts. 4. With wheels in a straight ahead position, center the steering shaft in the column. 5. Center boot and floor plate and tighten screws. 6. Torque the steering column bracket bolts to 30 ft lb. 7. Install steering wheel with master splines aligned and torque nut to 27 ft lb. Do not drive wheel onto shaft, use nut to draw it down. 8. Install horn switch parts, connect battery ground cable and check operation of lights and horn. Locations Oxygen Sensor: Locations Engine Mounted Switches & Sensors. Lower RH Side Of Engine Applicable to: V8 Engine Page 501 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. Page 275 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). Page 3842 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 Page 1370 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). Page 1542 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 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. 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. 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.) Page 3649 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. Page 1540 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 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, Page 3828 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. Page 1500 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) Specifications Brake Caliper: Specifications Adapter Mounting Bolts 150 ft.lb Retainer And Anti-rattle Spring 200 in.lb Page 1074 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Page 3870 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 Page 3118 7. Carefully remove plastic cover from lock plate, then depress lock plate and pry retaining ring out of groove with a screwdriver. Tool C-4156 can be used to depress lock plate, however, it will make removal of retaining ring more difficult, since the full load of the retaining plate will not be applied, allowing the retaining ring to turn. 8. Remove lock plate, cancelling cam and upper bearing spring. 9. Remove the three turn signal switch retaining screws, then place shift bowl in Low position. Wrap tape around connector wires to prevent snagging of wires, then remove switch and wiring. 10. Insert a small screwdriver into slot next to switch mounting screw boss (right hand slot) and depress spring latch at bottom of slot to release lock, then remove lock. The lock cylinder may be removed in any position from Accessory to On. However, the Lock position is recommended because of its positive location. Fig. 21 Steering column electrical connectors. Front wheel drive Mini-Vans/Wagons Fig. 22 Tilt spring retainer removal Fig. 23 Pivot pin removal 11. If used, remove buzzer and combination switch, by pulling it straight out using a piece of stiff wire with a hook bent at one end. Insert wire in exposed loop at wedge spring, then pull straight out. If lock cylinder has not been removed yet, place it in the On position. 12. Remove the three housing cover screws and housing cover. 13. Install tilt release lever and place column in full up position, then remove tilt spring retainer using a suitable screwdriver. Insert screwdriver in opening, press in about 3/16 inch and turn 1/8 inch turn until ears align with grooves in housing and remove spring and guide. 14. Push upper steering shaft to allow removal of steering shaft inner race and seat. 15. With ignition switch in Accessory position, remove ignition switch mounting screws and switch. 16. Place pivot pin remover C-4016 or equivalent over pivot pin and thread small portion of screw firmly into pin. While holding screw from turning, turn nut clockwise to remove pin from support. Remove opposite pin in same manner. 17. Using tilt release lever, disengage lock shoes, then remove bearing housing assembly by pulling upward to extend rack fully. Move housing assembly to the left to disengage rack from actuator and remove activator assembly. 18. Remove coupling from lower end of steering shaft by removing retaining pin. Page 99 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. Page 1130 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 Page 2207 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. Page 1115 FIGURE 3-A 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. Page 3610 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 Removal & Installation Crankshaft Position Sensor: Service and Repair 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. Page 1177 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 Page 613 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. Page 985 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 Page 2805 Fig 7 Removing Or Installing Inboard 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 in lb (22.6 Nm). Fig 1 Disc Brake Assembly (Rear View) 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. 6. Bleed brakes. 7. Pump brake pedal several times until a firm pedal has been obtained. 8. After bleeding caliper, check for fluid tightness under maximum pedal pressures. (Recheck master cylinder reservoir level). 9. Install wheel and tire assembly. Tighten stud nuts. 10. Remove jackstands or lower hoist. 11. Road test vehicle and make several stops to wear off any foreign material on the brakes and to seat the linings. Page 742 11. Install new cover and screws with "O" rings, PN 4411998. 12. Torque the cover screws to 40-50 inch pounds (4.5 - 5.6 N-m). 13. Check the hubs for locking/unlocking. POLICY: Information only Rotor Removal and Installation Brake Disc: Service and Repair Rotor Removal and Installation With Full Time 4WD Fig. 1 Using puller to remove hub & rotor. 44 FBJ Units w/disc brakes. Models w/full time 4WD Fig. 2 Removing outer bearing cone. 44 FBJ Units w/disc brakes. Models w/full time 4WD Fig. 3 Removing bearing retainer. 44 FBJ Units w/disc brakes. Models w/full time 4WD Page 2649 FIGURE 2 - Shift Rails and Shift Forks 2. Shift Rails and Shift Forks With the change of shift pattern, the shift rails have been relocated as shown in Figure 2. Therefore, the shift lugs, shift rails, shift forks, etc. have been changed. Furthermore, the return plunger above the adapter has been changed and the neutral return plunger (B) and resistance have been added (Figure 2). FIGURE 3 - Rear Bearing Retainer 3. Rear Bearing Retainer A hole has been made for the 3-4 speed shift rail. This hole is to prevent the interlock plunger (B) from coming out when the shift rail is shifted to the 3rd speed (Figure 3). Page 3159 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 Page 983 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. 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. 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 Page 3053 Circuit Breaker: Service and Repair Door Lock And Power Window Circuit Breaker And Relays Location Disconnect the battery negative terminal. Remove the two wires from the circuit breaker and remove the circuit breaker from its mounting clip. Install new circuit breaker to the mounting clip and connect the two wires. Connect the battery negative terminal and test power door lock system for proper operation. Page 2297 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) Page 3121 Inspection 1. Clean all parts in suitable solvent and inspect parts for damage. 2. Inspect bearings for damage or wear. 3. Inspect centering sphere for nicks, damage or wear. If damage is found, check shaft couplings for nicks, burrs or rough spots. 4. Inspect actuator housing, shift lever bowl and support for cracks or other damage. 5. Inspect turn signal switch for distorted, broken or damaged parts. 6. Inspect horn and turn signal switch wires for worn or bare spots. 7. Inspect steering shaft and gearshift tube for loose or broken plastic shear joints. Locations Idle Speed/Throttle Actuator - Electronic: Locations Engine Mounted Switches & Sensors. On Carburetor Applicable to: V8 Engine Page 1095 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. Page 2719 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. Page 1670 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 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. Page 3599 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. Locations Distributor Vacuum Control: Locations Orifice Spark Advance Control (OSAC) Valve Location. In Air Cleaner Housing Applicable to: V8 Engine Page 3400 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. Page 1531 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). Page 2303 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 Page 3168 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. Page 2538 Differential Axle Housing: Service and Repair Rear Axle Replace 1. Raise and support vehicle, then block brake pedal in the up position using a suitable block of wood. 2. Remove rear wheels, then the axle shafts, hub and drum assembly if equipped with Spicer axle. 3. Disconnect hydraulic brake lines at wheel cylinder. Cap fittings to prevent loss of brake fluid. 4. Disconnect parking brake cables, if necessary. 5. Scribe alignment marks on the propeller shaft universal joint and pinion flange to ensure correct position during installation. Disconnect propeller shaft at differential pinion flange and secure to one side. 6. Remove shock absorbers from spring plate studs, then the rear spring U-bolts. 7. Remove axle assembly from vehicle. 8. Reverse procedure to install. Page 3044 Fig. 29 Engine Compartment Electronic Spark Advance (W/Feedback Carburetor, Part 3 of 3) Wiring Circuit. 1983-84 Page 1205 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. Page 2901 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. Removal and Installation Brake Caliper: Service and Repair Removal and Installation Removal Fig 1 Disc Brake Assembly (Rear View) NOTE: It will be 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 5 Removing Or Installing Caliper 7. Carefully slide caliper out and away from disc and adaptor. Installation Page 1765 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. Specifications Intake Manifold: Specifications Intake Manifold 40 ft.lb Diagram Information and Instructions Steering Column: 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. Specifications Page 3406 (zero resistance) in the other lock knob position. If the door switch does not test properly, it is defective. Page 109 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 Page 887 Oil Pump: Specifications Oil Pump Mounting Bolts 30 ft.lb Page 3675 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. Page 2164 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Page 3380 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. Page 1192 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 Page 260 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. Page 4032 Power Window Circuit Breaker: Service and Repair Door Lock And Power Window Circuit Breaker And Relays Location Disconnect the battery negative terminal. Remove the two wires from the circuit breaker and remove the circuit breaker from its mounting clip. Install new circuit breaker to the mounting clip and connect the two wires. Connect the battery negative terminal and test system for proper operation. Page 2810 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. Page 2039 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 Page 82 *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 Page 2035 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). Page 1521 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 Page 1847 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. 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. Page 2818 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. Page 1124 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 Locations Clutch Switch: Locations On Clutch Pedal Page 2286 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. Page 4030 Power Window Circuit Breaker: Locations Door Lock And Power Window Circuit Breaker And Relays Location The circuit breaker is located behind the dash panel, to the left of the glove box. Page 3628 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. Page 35 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. Page 3637 *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 Page 2280 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. Locations Clutch Switch: Locations On Clutch Pedal Page 2776 13. Install shoe-to-shoe spring between shoes. 14. Engage primary shoe first with coil forward, opposite adjuster lever. 15. Install adjusting lever spring over pivot pin on shoe web. Install adjusting lever under spring and over pivot pin. Slide lever slightly rearward to lock in position. 16. Using Tool C-4070, or equivalent, install shoe retaining nails, retainers and springs. 17. Thread adjuster cable over guide and hook end of overload spring in lever. - Be sure eye of cable is pulled tight against anchor and in a straight line with guide. Page 1538 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 Page 2341 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. Page 1923 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. 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: Page 3857 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS 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. Page 3773 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. Page 2082 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 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: Piston Clearance Piston: Specifications Piston Clearance .0005-.0015 in Page 58 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. 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. Page 3830 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). Page 1216 Engine Control Module: Locations Engine Control Module Combustion Control Computer Location. Upper RH Side Of Engine Applicable to: 1981-84 Auto Locking Hubs - Not Locking/Unlocking Wheel Hub (Locking): All Technical Service Bulletins Auto Locking Hubs - Not Locking/Unlocking Models 1981-1984 "W" Model Trucks Equipped With Automatic Locking Hubs Subject Automatic Locking Hubs Will Not Operate During Low Temperatures Index FRONT SUSPENSION Date October 28, 1985 No. 02-10-85 SYMPTOM/CONDITION Customer concern of automatic locking hubs not locking/unlocking during below freezing weather. DIAGNOSIS Road test the vehicle and check for hubs locking/unlocking. NOTE: IF AMBIENT TEMPERATURES ARE ABOVE FREEZING, THE HUBS MAY OPERATE PROPERLY, THEN VISUAL INSPECTION IS REQUIRED. REMOVE THE COVER FROM THE HUB. INSPECT THE HUB FOR THE PRESENCE OF WATER CONTAMINATION. THIS WILL APPEAR IN THE FORM OF DISCOLORED GREASE OR RUST. If the hub is water contaminated, perform the following operation: PARTS REQUIRED Hub Repair Package PN 4411998 (as required) REPAIR PROCEDURE 1. Remove hub from axle. 2. Inspect the hub carefully to determine the extent of the water damage. If the hub components are corroded beyond repair, replace the hub assembly with new hub, PN 4384120. If damage to the hub is light, do the following: 3. Disassemble the hub and clean thoroughly to remove all contaminants Refer to Rear Wheel Drive Truck Service Manual for service procedure. 4. Inspect all components, especially the drag sleeve, brake band, and inner and outer cages for damage. Replace as necessary. 5. Reassemble the hub. 6. Lubricate the hub by dipping all components except the bearing and race assembly, brake band, and drag sleeve assembly in automatic transmission fluid. 7. Allow the excess transmission fluid to drip off. 8. Repack the bearing and race assembly with Darmex Lubricant, PN 4293040. 9. Lubricate the brake band and drag sleeve with Darmex Lubricant, PN 4293040. IMPORTANT: DO NOT SUBSTITUTE ANY OTHER LUBRICANT FOR THE DARMEX LUBRICANT SPECIFIED IN STEPS 8 AND 9, OR FAILURE OF THE HUB TO OPERATE PROPERLY COULD RESULT. 10. Reassemble and install the hub as outlined in the service manual. Page 1042 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.) Page 3622 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). Page 1675 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). Page 1343 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) Page 2558 Fig. 21 Removing or replacing axle shaft. 60 Front Axle Fig. 22 Removing or replacing upper socket pin. 60 Front Axle 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 Page 1141 FIGURE 3D - BODY WIRING Page 963 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. Page 2941 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 Page 1114 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. Page 63 FIGURE 3C - BODY WIRING Page 2301 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. Page 3532 Fig. 3 Speed control wiring diagram. 1981-84 Ramcharger, Trail Duster & Conventional Cabs Page 3836 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 Page 2099 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 Page 1474 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. Page 1974 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 Electrical Specifications Page 115 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. Page 3128 3. Pull body off shaft and shoe assembly. INSPECTION 1. Clean all parts in suitable solvent then inspect for wear or damage. 2. Inspect condition of shift lever gate and inner end of shift lever. 3. Inspect turn signal switch for distortion, broken or damaged parts. 4. Inspect steering shaft bearings for smooth operation. Replace bearing if it is rough or worn. ASSEMBLY During assembly, apply a thin coat of NLGI grade E.P. 2 or equivalent grease to all friction surfaces. 1. Clamp column in a vise so that both ends are accessible. 2. Check column tube-to-mandrel rivets for tightness. If loose, replace using 1/8 inch diameter by 1/4 inch long (1/8 inch grip) rivets. When replacing rivets, make sure to use ones of the same type material as removed. 3. Install floor plate and grommet on lower end of column jacket. 4. On automatic transmission columns: a. Place gearshift housing on column jacket, then with dust seal and shift tube support installed on shift tube, slide assembly into jacket. Guide key on upper end of tube into slot in gearshift housing. b. Position crossover load spring and shift lever in gearshift housing and tap the pivot pin into place. c. Install shift lever gate on lock housing. d. If used, feed gear selector dial lamp wire through hole behind transmission dial on lock housing and route wire down through space between housing and jacket. Secure lamp assembly to rear of dial with 2 screws and install lens. e. With shift lever in mid-position, seat lock housing on top of jacket, indexing key in housing with slot in jacket. Install and alternately tighten all 4 screws to insure proper seating of housing, then torque to 90 inch lbs. f. Install indicator bracket. 5. Grease and assemble the two lock levers, lock lever spring and pin, then install assembly in housing. Seat pin firmly into bottom of slots, making sure that lock lever spring leg is firmly in place in lock casting notch. 6. Install lock lever guide plate and retaining screws. 7. Position ignition switch to center detent (Off) position and shift lever in Park (Reverse for manual transmission columns). Feed wires down through space between housing and jacket, then position switch in housing and tighten the 3 retaining screws. 8. To install ignition lock, turn ignition lock to "Lock" position and remove key. The cylinder will move inward and a spring loaded retainer will snap into place, locking the cylinder to the housing. Fig. 14 Steering shaft pot coupling exploded view 9. To assemble steering shaft "Pot" coupling: a. Fill coupling body about 1/2 full with NLGI grade 2 E.P. or equivalent grease. b. Place cover and seal on shaft. c. Press shoe pin into steering shaft so that it projects an equal mount on each side of shaft. d. Place spring on side of shaft and over the shoe pin, then place shoes on pin ends with flat side toward spring, engaging tangs. e. Squeeze shoes together to compress spring and push assembly into coupling. Align master spline mark of coupling body with master spline on upper shaft. f. Drive in a new roll pin until flush with outer surface of coupling body. g. Position seal and cover on body and crimp cover tangs securely over projections on body. h. Move shaft in and out several times to distribute lubricant. 10. Install bearing support (floor shift), bearing and spring on steering shaft and insert the steering shaft assembly into the column. 11. Install steering column shaft lock plate sleeve over shaft lock plate pin. Do not hammer column shaft lock plate sleeve, as damage to the telescoping shaft may result. 12. Install coil spring or bearing lower snap ring. 13. Install ignition key lamp assembly into bearing housing. 14. Place rubber insulator with grounding staple over column upper bearing and install assembly into bearing housing bore. Use lubricant to ease installation. 15. Install turn signal switch into bearing housing, while feeding the wires through opening in housing. Also feed the ignition key lamp wires through the opening. 16. Install retaining plate over the switch and torque the retaining screws to 27 - 30 inch lbs. 17. Install turn signal lever. If equipped with speed control, feed wires through opening provided in the bearing housing. 18. Place bearing housing assembly on steering shaft, while feeding the wires through the opening between lower housings and jacket. 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. Page 3319 FIGURE 1 3. Pull the antenna plug out of the ferrule about 1/8" (Figure 1). If the radio starts playing, remove radio and send to a warranty repair station. Mark the repair order: ANTENNA FERRULE PROBLEM If the radio does not play when the antenna plug was pulled out 1/8", substitute a known good antenna to determine if the car antenna is defective. POLICY: Information only Page 1986 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. Page 3864 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. Page 1353 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. Page 350 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* Page 621 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 Page 3638 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 Page 1475 FIGURE 3D - BODY WIRING Page 3806 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. Page 3119 Fig. 24 Steering shaft centering spheres & anti-lash spring Fig. 25 Shift tube removal. Except front wheel drive Fig. 26 Sector & bolt spring assembly 19. Remove steering shaft assembly through upper end of column. 20. Disassemble steering shaft assembly by removing center spheres and anti-lash springs. 21. Remove the 4 support to lock plate retaining screws and remove support from end of column and jacket. If necessary, remove the 2 retaining screws and shift gate from support. 22. Remove shift tube retaining ring using a screwdriver, then remove thrust washer. On floor mounted gearshift lever assemblies, it will be noticed that there is no shift tube after the support is removed from the steering column jacket. The lock system actuator and spring can be lifted from the top end portion of the steering column jacket. 23. Using tool C-4120 or equivalent and bushing, remove shift tube from bowl. Do not hammer or pull on lower or upper shift tube as plastic joint may be sheared. 24. Remove shift tube from jacket through lower end. 25. Remove lock plate by sliding out of jacket notches and tipping down toward bowl hub at a 12 o'clock position and under jacket opening, then remove wave washer. 26. Remove bowl from jacket, then remove shift lever from bowl by winding spring up with pliers and pulling out. 27. Remove tilt lever opening shield from bearing housing. 28. Remove lock bolt spring by removing spring retaining screw and moving spring clockwise to remove from bolt. 29. Remove snap ring from sector drive shaft, then using a hammer and punch, lightly tap drive shaft from sector. Remove drive shaft, sector, bolt, rack and spring (also shim if used). 30. Drive out tilt release lever pin, then remove lever and release spring. To relieve load on release lever, hold shoes inward and wedge block between top of shoes (over slots) and bearing housing. 31. Remove lock shoe pin, then remove lock shoes and springs. 32. Remove bearings from housing only if they are to be replaced. Remove separator and balls from bearing. Place housing on a flat surface, then with a pointed punch against the back surface of race, carefully drive out race until a puller can be used. Repeat for other race. Page 1656 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. Page 832 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. 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. Locations Pulsair Valve: Locations Upper LH Side Of Engine 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. 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: Page 3847 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). Page 2037 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Page 1637 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 Page 3998 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. Page 3614 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). 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. Engine - Valve Train Noise Rocker Arm Assembly: Customer Interest Engine - Valve Train Noise Models 1984 Rear Wheel Drive Passenger Car Equipped W/318 Engine; 1984 Rear Wheel Drive Truck & Vans Equipped W/318 or 360 Engine Subject Valve Rocker Arm Breakage Index ENGINE Date December 21, 1984 No.. 09-11-84 SYMPTOM/CONDITION Noise in valve train. DIAGNOSIS Remove valve cover and inspect rocker arms for breakage in the push rod area. The push rod may have penetrated the rocker arm. PARTS REQUIRED Passenger Car & Truck 8 - Rocker Arm PN 4100774 8 - Rocker Arm PN 4100775 REPAIR PROCEDURE When a rocker arm is found to have failed in the above manner in the subject model engines, it is necessary to replace all 16 rocker arms and inspect the push rods. 1. Remove valve covers. 2. Remove all rocker arms and replace with new ones. 3. Inspect push rods and replace as necessary. 4. Reinstall rocker shafts and torque screws to 25 foot pounds (34 N-m). 5. Replace valve cover gaskets and reinstall valve covers. Tighten valve cover screws to 80 inch pounds (9 N-m). POLICY: Information only Page 2077 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 Page 1172 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 Page 1671 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 Page 1973 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 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. Page 2223 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 Page 2761 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. Page 140 Engine Control Module: Locations Engine Control Module Combustion Control Computer Location. Upper RH Side Of Engine Applicable to: 1981-84 Page 540 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. Locations Detonation (Knock) Sensor: Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Page 113 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). Page 1371 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. Page 3970 Fig. 11 Clearance & Identification Lamps Sweptline Box Wiring Circuits. 1983-84 W/Dual Rear Wheels Page 3645 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) Locations Intake Air Temperature Switch: Locations Engine Mounted Switches & Sensors. Upper RH Side Of Engine Page 279 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. Diagram Information and Instructions Engine 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. Electronic Control Unit Engine Control Module: Locations Electronic Control Unit Electronic Ignition System Components On Firewall Page 872 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. Page 3861 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 Page 2851 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) Page 870 Fig. 37 Oil Lamp With Gauge Cluster Wiring Circuit. 1984 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. Page 3129 19. Install bearing on steering shaft. Do not hammer shaft into the bearing or bearing onto shaft as damage to steering column or shaft may result. 20. Install upper snap ring on shaft, then install and torque the 3 bearing housing to lock housing screws to 35 inch lbs. 21. Install wiring trough in place over wires, being careful not to pinch wires between trough and jacket. Page 232 Fig. 8 Speed control wiring diagram. 1986-87 Conventional Cabs & Ramchargers Page 1483 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. Page 114 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). Electrical Specifications Battery: Electrical Specifications Standard Battery Standard Battery BCI Group Number 25 Cranking Performance 370 A Optional Battery Optional Battery BCI Group Number 24 Cranking Performance 500 A Page 3807 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 Fuel Pressure Regulator - Clicking/Tapping Noise Fuel Pressure Regulator: Customer Interest Fuel Pressure Regulator - Clicking/Tapping Noise Models 1984 Domestic Vehicles Equipped With Turbo Charged Engine Subject Pressure Regulator Clicking Noise Index FUEL Date December 3, 1984 No. 14-47-84 P-5297-C SYMPTOM/CONDITION Noises identified as "clicking", "tapping", or "rattling" may be caused by the fuel pressure regulator. Pulsing from the regulator can be transmitted into the fuel tubes and thus transmitted into the passenger compartment. This noise is most noticeable at idle or just off idle. PARTS REQUIRED Damper Package PN 4203640 Consists of: 1 - Damper & Hose Assembly PN 4203639 2 - Clamps PN 6500650 Must be ordered separately: 1 - Authorized Modification Label PN 4275086 REPAIR PROCEDURE 1. Bleed off fuel pressure from system.. 2. Remove outlet hose from the fuel pressure regulator. 3. Remove nut attaching regulator to regulator bracket and save for reassembly. Page 3472 Fig. 5 Speed control wiring diagram. 1984 Mini-Vans/Wagons (1985 similar) Page 1694 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. 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. Page 542 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 Page 3503 Fig. 4 Speed control wiring diagram. 1982-84 Rampage & 1983 Scamp Page 1257 Crankshaft Position Sensor: Service and Repair 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. Page 1455 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. Page 77 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. Page 2319 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. Page 1131 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 Page 3789 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 Page 3631 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 Page 1179 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 Page 254 FIGURE 3-A Diagram Information and Instructions Neutral Safety 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. Page 327 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. Page 2450 Crankshaft Position Sensor: Service and Repair Distributor Assembly 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. Page 3545 Fig. 5 Speed control wiring diagram. 1984 Mini-Vans/Wagons (1985 similar) Page 1365 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. Page 1173 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). Page 2513 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. Page 2103 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. Page 3154 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. Locations Oil Pressure Sender: Locations Engine Mounted Switches & Sensors. Top Of Engine Applicable to: V8 Engine Page 2249 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 Page 1165 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. 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, Front Axle Service Differential Axle Housing: Service and Repair Front Axle Service Remove & Replace 1. Secure brake pedal in the up position, then raise vehicle. 2. Disconnect front drive shaft at drive pinion yoke. 3. Disconnect drag link at steering knuckle arm (left side only). 4. Disconnect and plug brake line at frame crossmember. 5. Disconnect shock absorbers at lower mounts then disconnect sway bar link assembly, if equipped, from spring plates. 6. Remove nuts and washers from universal bolt spring clips, then remove axle from vehicle. 7. Reverse procedure to install axle assembly. Lubricate all fittings, free brake pedal and bleed brakes. 8. Lower vehicle and check front wheel alignment. Page 1984 FIGURE 3-A Page 524 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 Page 539 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. Page 1528 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. Page 1825 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. Diagram Information and Instructions Trailer Connector: 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. Page 2316 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 Page 2044 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 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: Locations Oxygen Sensor: Locations Engine Mounted Switches & Sensors. Lower RH Side Of Engine Applicable to: V8 Engine Page 2788 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. Page 4046 Power Window Switch: Service and Repair Door Components Locations Oil Pressure Sender: Locations Engine Mounted Switches & Sensors. Top Of Engine Applicable to: V8 Engine Page 2904 Fig. 11 Spool valve, power piston/accumulator and seal, assembly & disassembly Page 2214 FIGURE 3D - BODY WIRING Page 1533 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Page 460 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. Page 221 Fig. 8 Speed control wiring diagram. 1986-87 Conventional Cabs & Ramchargers Auto Locking Hubs - Not Locking/Unlocking Wheel Hub (Locking): All Technical Service Bulletins Auto Locking Hubs - Not Locking/Unlocking Models 1981-1984 "W" Model Trucks Equipped With Automatic Locking Hubs Subject Automatic Locking Hubs Will Not Operate During Low Temperatures Index FRONT SUSPENSION Date October 28, 1985 No. 02-10-85 SYMPTOM/CONDITION Customer concern of automatic locking hubs not locking/unlocking during below freezing weather. DIAGNOSIS Road test the vehicle and check for hubs locking/unlocking. NOTE: IF AMBIENT TEMPERATURES ARE ABOVE FREEZING, THE HUBS MAY OPERATE PROPERLY, THEN VISUAL INSPECTION IS REQUIRED. REMOVE THE COVER FROM THE HUB. INSPECT THE HUB FOR THE PRESENCE OF WATER CONTAMINATION. THIS WILL APPEAR IN THE FORM OF DISCOLORED GREASE OR RUST. If the hub is water contaminated, perform the following operation: PARTS REQUIRED Hub Repair Package PN 4411998 (as required) REPAIR PROCEDURE 1. Remove hub from axle. 2. Inspect the hub carefully to determine the extent of the water damage. If the hub components are corroded beyond repair, replace the hub assembly with new hub, PN 4384120. If damage to the hub is light, do the following: 3. Disassemble the hub and clean thoroughly to remove all contaminants Refer to Rear Wheel Drive Truck Service Manual for service procedure. 4. Inspect all components, especially the drag sleeve, brake band, and inner and outer cages for damage. Replace as necessary. 5. Reassemble the hub. 6. Lubricate the hub by dipping all components except the bearing and race assembly, brake band, and drag sleeve assembly in automatic transmission fluid. 7. Allow the excess transmission fluid to drip off. 8. Repack the bearing and race assembly with Darmex Lubricant, PN 4293040. 9. Lubricate the brake band and drag sleeve with Darmex Lubricant, PN 4293040. IMPORTANT: DO NOT SUBSTITUTE ANY OTHER LUBRICANT FOR THE DARMEX LUBRICANT SPECIFIED IN STEPS 8 AND 9, OR FAILURE OF THE HUB TO OPERATE PROPERLY COULD RESULT. 10. Reassemble and install the hub as outlined in the service manual. Page 1628 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). Page 1970 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. Page 592 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. Page 2727 - 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 in (23.8mm) - Allow for Wear 0.030 in (0.762mm) - Do Not Reface Beyond 0.970 in (24.6mm) 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. Page 3679 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Page 3745 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. Diagram Information and Instructions License Plate 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. Page 2226 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. Page 308 FIGURE 3-A Page 1146 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Page 91 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). Page 330 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. 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. Page 2726 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. - Reface both sides of rotor, not exceeding 0.030 (0.762mm) total. NOTE: All rotors (disc) will show marking of minimum allowable thickness cast on the un-machined surface. Page 2104 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 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: Page 284 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Page 3686 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. Page 2176 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* Page 3537 Fig. 8 Speed control wiring diagram. 1986-87 Conventional Cabs & Ramchargers Page 2270 FIGURE 3C - BODY WIRING Page 2335 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 Page 522 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 Page 3462 Fig. 7 Speed control wiring diagram. 1985 rear wheel drive Ram Van & Wagons Page 307 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. Page 2165 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Diagram Information and Instructions Neutral Safety 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. Page 3436 (zero resistance) in the other lock knob position. If the door switch does not test properly, it is defective. Page 3689 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. Page 3090 Fig. 9 Installing seal slinger on outer axle shaft. 44 FBJ Units w/disc brakes. Models w/full time 4WD Fig. 10 Installing lip seal on outer axle shaft. 44 FBJ Units w/disc brakes. Models w/full time 4WD Fig. 11 Using pry bar to retain axle shaft. 44 FBJ Units w/disc brakes. Models w/full time 4WD Assembly & Installation 1. Secure steering knuckle right side up in a vise and press upper and lower ball joints into position using proper tools. Install snap ring on lower joint and new boots on both joints. 2. Thread new sleeve into ball joint yoke on axle housing ensuring that two threads are exposed at the top. 3. Position steering knuckle on axle housing yoke, then install a new lower ball joint nut and torque to 80 ft-lbs. 4. Use Tool No. C-4169 and a torque wrench to torque sleeve in upper ball joint yoke to 40 ft-lbs, then install upper ball joint nut and torque to 100 ft-lbs. Install cotter pin if slot in nuts and hole in stud align. If not, tighten, do not loosen nut to align. 5. On left side only, position steering knuckle arm over studs on steering knuckle. Install tapered dowels and nuts, then torque nuts to 90 ft-lbs. Secure drag link to steering knuckle arm and torque nut to 60 ft-lbs. 6. Secure tie rod end to steering knuckle. Torque nut to 45 ft-lbs. 7. Install brake dust shield, if removed. 8. Inspect outer axle shaft seal surface for grooving. If surface is grooved, repair as described in "Servicing Rotor Hub or Bearings". 9. Apply RTV sealer to seal surface of axle shaft then using driver, C-4398-1, install seal slinger with lip toward splines onto outer axle shaft. 10. Carefully insert axle shaft into housing so as not to damage differential seal at side gears. After sliding axle shaft completely in, wedge a pry bar through universal joint to retain shaft. Page 69 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Page 2807 Brake Caliper: Service and Repair Disassembly and Assembly Disassembly Fig. 11 Piston Seal Removal 1. To remove piston, support caliper assembly on steering knuckle on shop towels to absorb any hydraulic fluid loss. 2. Carefully depress brake pedal to hydraulically push piston out of bore (brake pedal will fall away when piston has passed bore opening) 3. 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. 4. 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. 5. Disconnect brake flexible hose from the caliper. 6. Mount caliper assembly in a vise equipped with protector jaws. CAUTION: Excessive vise pressure will cause bore distortion and binding of piston. 7. Remove dust boot using suitable tool. 8. Using a small, pointed, wooden or plastic rod, 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 Page 1112 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) Page 3531 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 Page 3271 2. Remove screws holding blower motor to heater housing on firewall. 3. Remove blower. 4. Reverse procedure to install. Page 3148 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. Page 1681 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. Page 274 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). Page 3615 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). 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. Page 1522 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. Page 1194 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. Page 3814 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* Page 3876 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. 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. Page 2832 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. 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 Page 3399 Power Door Lock Relay: Locations Electric Door Lock Relays Electric Door Lock Relay Location. Behind LH Side Of I/P Applicable to: 1981-84 Page 2149 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 Page 3526 Fig. 9 Speed control wiring diagram. 1986 rear wheel drive Ram Van & Wagons Locations Detonation (Knock) Sensor: Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Page 1504 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. 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. Page 2049 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* Page 1615 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 Page 1139 FIGURE 3C - BODY WIRING Page 215 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 Page 3704 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 Page 233 Fig. 9 Speed control wiring diagram. 1986 rear wheel drive Ram Van & Wagons Page 607 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. Page 2150 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 Page 3040 Fig. 27 Engine Compartment ECU Ignition Wiring Circuit. 1983-84 W/V8 Engine Page 1493 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 Page 1659 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. Page 3522 Fig. 5 Speed control wiring diagram. 1984 Mini-Vans/Wagons (1985 similar) Page 1934 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 Page 3415 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. Page 1846 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. Specifications Page 2143 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 Page 3577 Fig. 31 Four Wheel Drive Indicator Lamp Wiring Circuit. 1983-84 Page 204 Fig. 3 Speed control wiring diagram. 1981-84 Ramcharger, Trail Duster & Conventional Cabs Page 2005 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). Page 281 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. Locations Detonation (Knock) Sensor: Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Page 343 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 Page 108 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 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 Page 2220 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 Page 178 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 Page 2243 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) Page 1158 *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 Page 3435 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 Page 914 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. Page 2964 Fig. 7 Alternator & electronic voltage regulator diagnosis chart Diagram Information and Instructions EGR 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. Page 1342 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. Electrical Specifications Ignition Control Module: Electrical Specifications Part No. Spark Advance Test Electronic EGR Time Delay Electronic Throttle Control 4289075 44 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289077 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289086 44 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289094 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289304 39 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289308 43 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289310 42 +/- 4 deg at 2000 rpm 20 min 20 sec 4289324 20 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289326 21 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289351 39 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289352 43 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289356 20 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289357 21 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289364 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. Diagram Information and Instructions Trailer Lighting 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. Page 3676 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). Page 2033 FIGURE 3D - BODY WIRING Page 121 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). Specifications Fig. 4 Fusible Link Connector. 1983-84 Page 1144 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). Battery & Charging System - General Information 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 Page 3681 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. Page 1644 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 Page 2562 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. Page 881 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. 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: Page 1086 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". Page 2332 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 Page 3463 Fig. 8 Speed control wiring diagram. 1986-87 Conventional Cabs & Ramchargers Page 103 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 Transaxle/Transmission - Automatic Fluid - A/T: Specifications Transaxle/Transmission - Automatic TYPE.................................................................................................................................................... ........................................................................AF, AP CAPACITY, Initial Refill*: All models w/o torque converter drain..............................................................................................................................................3.8 Liters 4.0 Quarts *With the engine at operating temperature, shift transmission through all gears. Check fluid level in PARK and add fluid as needed Specifications 4 Barrel Carburetor Page 1366 FIGURE 3-A Diagram Information and Instructions Trailer Lighting 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. 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. Locations Page 288 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. Page 3414 Page 1208 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 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. 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. Page 1672 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 Page 3505 Fig. 6 Speed control wiring diagram. 1985 Conventional Cabs & Ramcharger Page 365 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. Page 3043 Fig. 29 Engine Compartment Electronic Spark Advance (W/Feedback Carburetor, Part 2 of 3) Wiring Circuit. 1983-84 Locations Idle Speed/Throttle Actuator - Electronic: Locations Engine Mounted Switches & Sensors. On Carburetor Applicable to: V8 Engine Page 2781 Fig 2 Rear Wheel Cylinder 11 And 12 Inch Brakes Page 3723 7. Open the odometer chip access door by pressing the latch ears toward the center of the door. FIGURE 1 8. Notice that the odometer chip located just inside the access door has a distinctive notch. Be sure to install the chip in the same direction it was in the original cluster. When installed properly, the odometer chip notch should be on the left (Figure 1). FIGURE 2 FIGURE 3 9. Using Miller Special Tool #C-4817 (Figure 2), grasp the chip between the tool jaws under the ends of the odometer chip. Carefully rock the chip along its longitudinal axis as you pull gently. The odometer chip should extract easily (Figure 3). NOTE: IF THE ODOMETER CHIP WILL NOT BE IMMEDIATELY INSTALLED IN THE NEW CLUSTER, PROTECT THE ODOMETER CHIP FROM DAMAGE BY PLACING IT IN AN ENVELOPE WITH THE VEHICLE VIN NUMBER AND MILEAGE. Page 2994 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. Page 1207 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. Page 2794 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. Service and Repair 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 Page 1375 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 Specifications Fluid - M/T: Specifications A833 OD............................................................................................................................................... .......................................................................AF, AP 75W, 75W-80, 80W-90, 85W-90, 90 GL-5 may be used NP435.......................................................... ......................................................................................................................................................GL-5 , SF, SG SF, 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 CAPACITY, Refill: NP435.................................. .............................................................................................................................................................. ....3.3 Liters 7.0 Pints A833 OD............................................................................................................................................... ................................................3.5 Liters 7.5 Pints Page 3651 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 Page 2030 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 Page 1067 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. Page 318 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 Page 1505 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. Page 1306 Crankshaft Position Sensor: Service and Repair 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. 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: 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 Page 1362 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. Wheel Cover - Loose/Falls Off Wheels: All Technical Service Bulletins Wheel Cover - Loose/Falls Off Models 1984 D, W & B 250 - 350 Dodge Pick-Up Trucks & Van/Wagons Subject Wheel Cover Retention With 16.5 x 6.75 H.D. Wheels Index WHEELS & TIRES Date November 12, 1984 No. 22-01-84 P-4993-C SYMPTOM/CONDITION A small number of subject vehicles may exhibit a condition of lack of wheel cover/hub cap retension on one or more of the wheels. The wheel covers/hub caps may not grip the embossment on the wheel, thus the cover will not stay on. This occurs primarily during installation at new vehicle pre-delivery. If the above condition occurs, the wheel must be replaced. PARTS REQUIRED 16.5 x 6.75 H.D. Wheel PN 4284446 NOTE: REPLACED WHEELS MUST BE RETURNED TO THE MATERIAL RETURN CENTER. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 22-40-01-02 . . . . . . . . . . . 0.6 Hrs. FAILURE CODE: HR - Improper Retention Specifications Page 1775 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. Page 3959 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 Page 1983 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. Page 4023 Power Window Switch: Testing and Inspection Remove both power window switches from their trim panels and remove the wiring harness from the back of each switch. Turn the ignition switch to the "run" position. Check for power and ground by connecting a test light between the TN and WT wires at the left switch harness and between the TN wire and ground of the right switch harness. If the test light does not illuminate or is dim, check the circuit breaker, relay, and wiring to the switch. Power Window Switch Test To test left switch function, connect jumper wires as shown to the right switch harness. 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 window motors do not operate properly, the window motors or wiring may be defective. To test the right switch function, connect a jumper wire between the WT and VT wires of the left window switch. Now connect a jumper wire between the TN and PK wires of the right window switch. The right window should move down. Disconnect the jumper wires and connect a jumper wire between the WT and PK wires at the left window switch. Now connect a jumper wire between the TN and VT wires of the right window switch. The right window should go up. If the window operates properly, the right window switch is defective. If the window does not operate properly, the window motor or wiring may be defective. 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: Page 3437 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). Page 1345 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. Page 2774 Fig 6 Removing Or Installing Parking Brake Strut And Spring 4. Slide parking brake strut behind axle flange and into slot in parking brake lever. Slide anti-rattle spring over free end of strut. 5. Slide primary shoe into position and engage with push rod (if so equipped) and free end of strut. Fig 7 Installing Brake Shoes 6. Install anchor plate over anchor, then install eye of adjuster cable over anchor. 7. Engage primary shoe return spring in web of shoe and install free end over anchor, using Tool C-3785 or equivalent. For additional information on brake spring removal/installation see Fundamentals and Basics. 8. Insert protruding hole rim of cable guide into hole in secondary shoe web. 9. Holding guide in position, engage secondary shoe return spring through both, hole in guide, and hole in web. Page 2092 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. Page 3850 FIGURE 3C - BODY WIRING Page 2023 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 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. Page 1346 FIGURE 3-A Page 1887 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 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. 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. Page 3793 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). Page 3598 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). Page 2782 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). Page 1601 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. Page 2192 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). Page 312 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). Page 2329 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). 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. Specifications Compression Check: Specifications Compression Check Specifications Compression Check Specifications Compression Pressure 100 psi At cranking speed, engine temperature normalized, throttle open Maximum Variation 40 psi Page 1502 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. Page 3636 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* Page 1454 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. Page 1657 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 Page 2065 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). Page 1471 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. Page 2473 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. Page 2605 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 Page 1125 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 Page 2206 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 Page 2895 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. Locations Stop Lamp Switch: Locations On Brake Pedal Page 1116 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. 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. Page 230 Fig. 6 Speed control wiring diagram. 1985 Conventional Cabs & Ramcharger Service and Repair 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 Page 620 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 Page 514 FIGURE 3-A 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. Page 3417 The next four spaces will be used to designate primary paint color (for 1984 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 1984 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 1984... Various paint manufacturer's 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. 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. Page 1544 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. Radio - No AM/Weak FM Reception Radio/Stereo: Technical Service Bulletins Radio - No AM/Weak FM Reception Models All 1984 Vehicles Equipped With Standard AM-FM Mux Radio (Sales Code RAL) Subject No AM and Weak FM Radio Reception Index ELECTRICAL Date February 14, 1984 No. 08-08-84 P-536 SYMPTOM/CONDITION Radio reception coming in weak on FM stations and not at all on AM stations may be due to the antenna plug short circuiting inside the radio. This condition is similar to a failed antenna. DIAGNOSIS To determine whether the radio or antenna is at fault: 1. To gain access to the back of the radio, slide the radio out of the instrument panel without disconnecting any wires. 2. Turn radio on and tune to a local AM station. Page 1607 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. Page 590 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. 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. Testing and Inspection 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 Page 1525 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. Page 3362 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 Locations Spark Control Relay: Locations Electronic Ignition System Components On Firewall Page 1485 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. Page 2193 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. Page 3630 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. Page 2108 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. Page 335 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. Page 49 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 Page 2972 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 Page 3848 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. Page 2415 Ignition Control Module: Mechanical Specifications Part No. Spark Advance Test Electronic EGR Time Delay Electronic Throttle Control 4289075 44 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289077 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289086 44 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289094 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289304 39 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289308 43 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289310 42 +/- 4 deg at 2000 rpm 20 min 20 sec 4289324 20 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289326 21 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289351 39 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289352 43 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289356 20 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289357 21 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289364 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. Page 2352 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. Page 1935 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. Page 2072 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. Page 2874 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). Page 2288 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* 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. Page 2785 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 Page 2299 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. Page 70 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS 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. Page 2064 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) Locations Stop Lamp Switch: Locations On Brake Pedal Page 3085 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. Page 2096 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). Specifications Engine Oil Drain Plug: Specifications Oil Drain Plug 25 ft.lb Page 76 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 Page 2704 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 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. Page 290 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. Page 1154 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 Page 1992 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 Page 2045 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. Specifications 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. 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. Page 2251 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. Page 1199 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Page 1478 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). Page 42 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 Page 960 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). Page 2619 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 Page 3150 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 Page 251 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) Page 2561 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 Page 891 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. Page 703 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. Page 970 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 Page 1807 Fig. 13 Unleaded fuel tank filler tube The catalytic converter is used to oxidize hydrocarbons (HC) and carbon monoxide (CO) in the exhaust system. The converter is constructed of a stainless steel shell containing two ceramic monolithic elements which are coated with a catalytic agent, Fig. 12. The combustion type reaction created by the catalyst releases additional heat in the exhaust system with temperatures up to 1600° F under normal operating conditions. This additional heat is needed for the catalyst to function properly. Special heat shields are used to protect chassis components and other areas from heat damage. Since the use of leaded fuels contaminates the catalysts, the use of unleaded fuels is mandatory in vehicles equipped with catalytic converters. A smaller diameter fuel tank filler tube is used to prevent the addition of leaded fuel into the fuel tank. In addition, a spring-loaded valve, Fig. 13, which is opened by the unleaded fuel nozzle, prevents the addition of fuel by other than the proper nozzle. Page 3162 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 Page 1782 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. Page 3140 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. Page 3965 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 Page 111 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 Electrical Specifications Ignition Control Module: Electrical Specifications Part No. Spark Advance Test Electronic EGR Time Delay Electronic Throttle Control 4289075 44 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289077 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289086 44 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289094 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289304 39 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289308 43 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289310 42 +/- 4 deg at 2000 rpm 20 min 20 sec 4289324 20 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289326 21 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289351 39 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289352 43 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289356 20 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289357 21 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289364 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. Page 471 Power Window Switch: Testing and Inspection Remove both power window switches from their trim panels and remove the wiring harness from the back of each switch. Turn the ignition switch to the "run" position. Check for power and ground by connecting a test light between the TN and WT wires at the left switch harness and between the TN wire and ground of the right switch harness. If the test light does not illuminate or is dim, check the circuit breaker, relay, and wiring to the switch. Power Window Switch Test To test left switch function, connect jumper wires as shown to the right switch harness. 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 window motors do not operate properly, the window motors or wiring may be defective. To test the right switch function, connect a jumper wire between the WT and VT wires of the left window switch. Now connect a jumper wire between the TN and PK wires of the right window switch. The right window should move down. Disconnect the jumper wires and connect a jumper wire between the WT and PK wires at the left window switch. Now connect a jumper wire between the TN and VT wires of the right window switch. The right window should go up. If the window operates properly, the right window switch is defective. If the window does not operate properly, the window motor or wiring may be defective. Page 1073 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb 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: Page 2210 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. Page 3511 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. 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 Crankshaft Journal Tolerances Crankshaft: Specifications Main and Rod Journal Diameters Main and Rod Journal Diameters Main Journal Diameter 2.8095-2.8195 in Rod Journal Diameter 2.124-2.125 in 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. 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. 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 Page 3612 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 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. Page 2512 FIGURE 1 - A604 TRANSAXLE FIGURE 2 - A413/A670 TRANSAXLE FIGURE 3 - REAR WHEEL DRIVE TRANSMISSION Page 3801 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). 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 Page 3644 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. Page 396 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. Locations Evaporative Emission Control Canister: Locations A sealed, maintenance free, charcoal canister is used on all engines and is located in the wheel well area of the engine compartment. Page 336 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). Page 2394 Crankshaft Position Sensor: Service and Repair 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. 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: Page 1898 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 Page 3680 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 Page 3077 Fig. 28 Engine Compartment Electrical Spark Advance (Less Feedback Carburetor, Part 1 of 3) Wiring Circuit. 1983-84 Electrical Specifications Page 520 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. Page 2717 Fig. 11 Piston Seal Removal - 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. Fig 8 Caliper Assembly 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. Page 1617 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 Page 3674 FIGURE 3D - BODY WIRING Page 649 Fluid - Differential: Specifications Differential Above 90°F (32°C), 140, 80W-140, 85W-140; above -10°F (-23°C), 90, 80W-90, 80W-140, 85W140; below -10°F (-23°C), 75W, 80W, 75W-90, 80W-140 REAR: Standard................................................................................................................................... ..........................................................................GL-5 Anti-Spin, Limited-Slip, Power-Loc, Sure-Grip, Trac-Loc.......................................................................................................................................90 GL-5* FRONT: 4 x 4....................................................................................................................................... .........................................................................GL-5 CAPACITY, Refill: Front: 4-wheel drive ex.Spicer 60F....................................................................................................................................... ................1.7 Liters 3.5 Pints Spicer 70.............................................................................................................................................. ..................................................3.1 Liters 6.5 Pints Rear: Spicer 60, 60 HD........................................................................................................................ ................................................2.8 Liters 6.0 Pints Spicer 70.............................................................................................................................................. ..................................................3.1 Liters 6.5 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 Page 3020 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. Page 67 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). Diagrams Timing Marks and Indicators: Diagrams TIMING MARK 1981-85 5.2L & 5.9L 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 Page 4041 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 support bracket. Install by attaching relay to the instrument panel support bracket and connecting the wires to the relay. Connect the battery negative terminal and test the system for proper operation. Page 3509 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. 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. 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. Auto Locking Hubs - Not Locking/Unlocking Wheel Hub (Locking): All Technical Service Bulletins Auto Locking Hubs - Not Locking/Unlocking Models 1981-1984 "W" Model Trucks Equipped With Automatic Locking Hubs Subject Automatic Locking Hubs Will Not Operate During Low Temperatures Index FRONT SUSPENSION Date October 28, 1985 No. 02-10-85 SYMPTOM/CONDITION Customer concern of automatic locking hubs not locking/unlocking during below freezing weather. DIAGNOSIS Road test the vehicle and check for hubs locking/unlocking. NOTE: IF AMBIENT TEMPERATURES ARE ABOVE FREEZING, THE HUBS MAY OPERATE PROPERLY, THEN VISUAL INSPECTION IS REQUIRED. REMOVE THE COVER FROM THE HUB. INSPECT THE HUB FOR THE PRESENCE OF WATER CONTAMINATION. THIS WILL APPEAR IN THE FORM OF DISCOLORED GREASE OR RUST. If the hub is water contaminated, perform the following operation: PARTS REQUIRED Hub Repair Package PN 4411998 (as required) REPAIR PROCEDURE 1. Remove hub from axle. 2. Inspect the hub carefully to determine the extent of the water damage. If the hub components are corroded beyond repair, replace the hub assembly with new hub, PN 4384120. If damage to the hub is light, do the following: 3. Disassemble the hub and clean thoroughly to remove all contaminants Refer to Rear Wheel Drive Truck Service Manual for service procedure. 4. Inspect all components, especially the drag sleeve, brake band, and inner and outer cages for damage. Replace as necessary. 5. Reassemble the hub. 6. Lubricate the hub by dipping all components except the bearing and race assembly, brake band, and drag sleeve assembly in automatic transmission fluid. 7. Allow the excess transmission fluid to drip off. 8. Repack the bearing and race assembly with Darmex Lubricant, PN 4293040. 9. Lubricate the brake band and drag sleeve with Darmex Lubricant, PN 4293040. IMPORTANT: DO NOT SUBSTITUTE ANY OTHER LUBRICANT FOR THE DARMEX LUBRICANT SPECIFIED IN STEPS 8 AND 9, OR FAILURE OF THE HUB TO OPERATE PROPERLY COULD RESULT. 10. Reassemble and install the hub as outlined in the service manual. Page 2860 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 Page 3600 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. Page 2682 Fig. 31 Four Wheel Drive Indicator Lamp Wiring Circuit. 1983-84 Removal & Installation Crankshaft Position Sensor: Service and Repair 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. Page 1930 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 Page 2737 Outer Locknut, Lockwasher And Inner Locknut Fig 1 Disc Brake Assembly (Rear View) 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 Page 1596 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. Page 1940 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 Page 2903 Fig. 10 Bracket, removal & installation Page 2036 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). 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. Page 1944 (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. Page 2246 FIGURE 3-A 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 Page 962 FIGURE 3-A Page 1056 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. 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. Page 3852 FIGURE 3D - BODY WIRING With A/C Blower Motor: Locations With A/C Heater & A/C System Components RH Side Of Engine Compartment Page 3070 Fig. 3 Bulkhead Connector (40 Way). 1983-84 Page 257 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 Page 1113 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). Page 1518 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 Page 2012 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. Page 2767 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 0.13mm (0.005 in.). Final Cut When the entire braking surface has been cleaned a final cut of 0.0254mm (0.001 in.) will assure a good drum surface, if 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. Page 1769 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. Page 89 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. Page 2014 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. Page 36 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) Page 538 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). Page 1994 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 Page 3796 FIGURE 3C - BODY WIRING Locations Intake Air Temperature Switch: Locations Engine Mounted Switches & Sensors. Upper RH Side Of Engine Page 2296 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. Service and Repair Ball Stud: Service and Repair Fig. 17 Using puller to remove tie rod (Typical) Fig. 18 Using puller to remove drag link from steering arm. (Typical) MODELS W/FULL TIME 4WD Removal & Disassembly 1. Remove axle shaft cotter pin and loosen outer axle shaft nut. 2. Raise vehicle, then remove wheel assembly. 3. After removing caliper retainer and anti-rattle spring assembly, slide caliper out and away from rotor. Hang caliper out of the way. Do not allow caliper to hang by hydraulic brake hose. Remove inboard brake pad. 4. Remove outer axle shaft nut and washer and through access hole in rotor assembly; remove the six bearing retainer bolts. 5. Secure a suitable puller to wheel studs and tighten main screw of tool to remove hub, rotor, bearings, retainer and outer seal as an assembly. Remove puller from rotor. 6. Remove brake caliper adapter from knuckle, then remove and discard O-ring from knuckle, if equipped. 7. Carefully pull axle shaft assembly out and remove seal and slinger from shaft. 8. Disconnect tie rod from steering knuckle using a suitable tool, so as not to damage seal. 9. On left side only, disconnect drag link from steering knuckle arm again using a suitable tool to avoid seal damage. 10. Remove nuts from steering knuckle arm on left side only. Tap arm to loosen tapered dowels. Remove dowels and arm. 11. Remove cotter pin from upper ball joint nut then remove upper and lower ball joint nuts. Discard lower nut. 12. Separate steering knuckle from axle housing yoke using a brass drift and a hammer, then, using a suitable tool, remove and discard sleeve from upper ball joint yoke on axle housing. 13. Secure steering knuckle uPSIde down in a vise and remove snap ring from lower ball joint. 14. Use proper tools to press upper and lower ball joints from steering knuckle. Replace ball joints if any looseness or endplay exists. Page 3076 Fig. 29 Engine Compartment Electronic Spark Advance (W/Feedback Carburetor, Part 3 of 3) Wiring Circuit. 1983-84 Page 3792 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). Page 1352 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. 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 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. Page 1878 LABEL SPECIFICATIONS, TYPE IN ON THE RIGHT HAND SIDE OF THE LABEL "REFER TO ORIGINAL VECI LABEL". IN EVERY CASE WHERE THIS LABEL IS USED, TYPE IN AFTER - AUTHORITY OF TECHNICAL SERVICE BULLETIN #25-05-84, AND YOUR DEALER CODE BELOW. LABEL PN 4275084 IS AVAILABLE FROM PARTS SUPPLY. Conversion Procedure 1. On the 360-4V only, replace the secondary metering jets with PN 4293720. 2. Relieve the tension on the secondary air valve spring by one turn clockwise (both 318 and 360). 3. Adjust the secondary air valve opening to 1/2" (both 318 and 360). 4. Reset basic timing from 4~ to 8~ BTD on 360-4V and from 8~ to 12~ BTD on 318-4V. 5. Reset idle and propane speeds to sea level specifications at altitude. 6. Refer to 1984 Rear Wheel Drive Truck Service Manual for correct procedures for the above adjustments. 7. Type Vehicle Emission Control Information Update Label, PN 4275084, as shown in Figure 1 and install next to or near the original VECI label. NOTE: VEHICLE SHOULD BE RETURNED TO ITS ORIGINAL CONDITION IF DRIVEN AT LOW ALTITUDE. POLICY: Information only Page 1686 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 Removal and Installation Brake Caliper: Service and Repair Removal and Installation Removal Fig 1 Disc Brake Assembly (Rear View) NOTE: It will be 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 5 Removing Or Installing Caliper 7. Carefully slide caliper out and away from disc and adaptor. Installation Page 2911 Vacuum Brake Booster: Service and Repair Transverse-Mounted Booster TRANSVERSE MOUNT 1. Disconnect vacuum hose from power booster. 2. Remove master cylinder to booster attaching nuts, then the master cylinder. 3. Remove booster pushrod to pivot attaching bolts. 4. Remove power booster attaching nuts, then the power booster assembly. 5. Reverse procedure to install. 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. Specifications Fluid - Transfer Case: Specifications NP205................................................................................................................................................... .............................................................GL-5, SF, SG SF, SG: Above 32°F 50; below 32°F (0°C), 30 GL-5: Above 90°F (32°C), 140; above -10°F (-23°C), 90; 90; below -10°F (-23°C), 80W NP208........ .............................................................................................................................................................. .....................................................AF, AP CAPACITY, Refill: NP205................................................... .................................................................................................................................................2.1 Liters 4.5 Pints NP208................................................................................................................................................... .................................................2.8 Liters 6.0 Pints 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. Page 2159 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. Diagrams Timing Marks and Indicators: Diagrams TIMING MARK 1981-85 5.2L & 5.9L Page 45 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. Page 615 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). Page 3425 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. Page 66 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. Page 1844 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. Page 657 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 Locations Detonation (Knock) Sensor: Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Page 1545 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* 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. Page 2105 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. 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. Page 3832 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. Page 75 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. Page 2213 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. Page 3672 FIGURE 3C - BODY WIRING Page 1626 FIGURE 3D - BODY WIRING Page 3151 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 Page 3678 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Wheel Cover - Loose/Falls Off Wheel Cover: All Technical Service Bulletins Wheel Cover - Loose/Falls Off Models 1984 D, W & B 250 - 350 Dodge Pick-Up Trucks & Van/Wagons Subject Wheel Cover Retention With 16.5 x 6.75 H.D. Wheels Index WHEELS & TIRES Date November 12, 1984 No. 22-01-84 P-4993-C SYMPTOM/CONDITION A small number of subject vehicles may exhibit a condition of lack of wheel cover/hub cap retension on one or more of the wheels. The wheel covers/hub caps may not grip the embossment on the wheel, thus the cover will not stay on. This occurs primarily during installation at new vehicle pre-delivery. If the above condition occurs, the wheel must be replaced. PARTS REQUIRED 16.5 x 6.75 H.D. Wheel PN 4284446 NOTE: REPLACED WHEELS MUST BE RETURNED TO THE MATERIAL RETURN CENTER. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 22-40-01-02 . . . . . . . . . . . 0.6 Hrs. FAILURE CODE: HR - Improper Retention 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. 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. Page 3791 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. 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. Page 116 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 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. Page 513 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. Page 1140 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. Page 1722 Crankshaft Position Sensor: Service and Repair 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. 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: Page 1091 Fig. 13 Unleaded fuel tank filler tube The catalytic converter is used to oxidize hydrocarbons (HC) and carbon monoxide (CO) in the exhaust system. The converter is constructed of a stainless steel shell containing two ceramic monolithic elements which are coated with a catalytic agent, Fig. 12. The combustion type reaction created by the catalyst releases additional heat in the exhaust system with temperatures up to 1600° F under normal operating conditions. This additional heat is needed for the catalyst to function properly. Special heat shields are used to protect chassis components and other areas from heat damage. Since the use of leaded fuels contaminates the catalysts, the use of unleaded fuels is mandatory in vehicles equipped with catalytic converters. A smaller diameter fuel tank filler tube is used to prevent the addition of leaded fuel into the fuel tank. In addition, a spring-loaded valve, Fig. 13, which is opened by the unleaded fuel nozzle, prevents the addition of fuel by other than the proper nozzle. Page 1153 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. Locations Spark Control Relay: Locations Electronic Ignition System Components On Firewall Page 3093 a. Remove disconnect housing cover, then position shift collar onto splined end of inner axle shaft. b. Install intermediate axle shaft through axle shaft seal. Use caution not to damage seal. c. Install disconnect housing cover assembly and gasket. Ensure shift fork is guided into groove of shift collar. d. Install disconnect cover shield and shield attaching bolts. Torque bolts to 10 ft-lbs. e. Connect vacuum lines and switch electrical connector. 13. Using tools D-122 and C-4171, install new needle bearings into spindle. 14. Fill seal area with NLGI grease or equivalent, and install seal with tools D-155 and C-4171. 15. Install new bronze spacer on axle shaft, install spindle and brake splash shield. 16. Install new nuts and torque to 25-35 ft-lbs. 17. Mount braking disc assembly and outer wheel bearing cone onto spindle. 18. Install wheel bearing nuts and locking washer. 19. Install locking hub assembly. 20. Install brake adapter and torque attaching bolts to 85 ft-lbs. 21. Install the assembled brake caliper assembly. 22. Install the wheel and torque the nuts to 110 ft-lbs. Lower vehicle and test operation. Page 2140 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. 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. Page 1170 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. Electrical Specifications Page 2836 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 Split Point (PSI)/Slope ............................................. ....................................................................................................................................... 300/0.27 ID tag color ............................................................................................................................................... ........................................................... White Page 1971 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. Page 4052 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. Page 1524 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). Page 521 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. Page 1643 *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 Specifications Fig. 4 Fusible Link Connector. 1983-84 Page 2017 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 Page 3775 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 Page 3163 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 Page 2315 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 Page 273 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. Page 2768 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. Page 234 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. Engine - High Altitude Conversion Package Air/Fuel Mixture: Technical Service Bulletins Engine - High Altitude Conversion Package Models 1984 318-4V & 360-4V Heavy Duty Truck Subject High Altitude Conversion Package & Adjustment for Improved Engine Performance Index EMISSIONS Date 11/12/84 No. 25-05-84 P-5036C A package is now available to accommodate a customer who wishes to convert his 1984 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 1984 non-altitude equipped engine families in service at altitudes above 4,000 feet above sea level.. CONVERSION INSTRUCTIONS Sea Level to Altitude IMPORTANT: IN SOME OF THE CONVERSION PROCEDURES YOU WILL BE REQUIRED TO INSTALL A NEW VEHICLE EMISSION CONTROL INFORMATION UPDATE (VECIU) LABEL, PN 4275084. FIGURE 1 THIS LABEL HAS TWO AREAS THAT ARE IMPACT IMPRINTABLE WITH A TYPEWRITER (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, THEN JUST TYPE IN THE NEW SPECIFICATION AFTER THE SUBJECT OPERATION. IF YOU ARE ASKED TO REFER TO THE ORIGINAL VECI Page 43 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). Page 482 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. Page 2958 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. Page 2266 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). Page 1123 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 Page 3937 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. Page 3617 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 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. Page 2618 Fig. 11 Alignment punch marks Fig. 17 Inserting cross into yoke Page 2056 FIGURE 1 4. Place damper assembly with attached bracket onto outlet end of pressure regulator and line up with locating notch (Figure 1) 5. Replace nut onto pressure regulator outlet nipple and torque to 100 inch pounds (+/-) 20 inch pounds. 6. Attach free end of formed hose onto pressure regulator with the supplied clamp and torque to 8-13 inch pounds. FIGURE 1 7. Return hose, originally attached to pressure regulator, should be reassembled onto outlet nipple of damper with remaining clamp. Torque to 8-13 inch pounds (Figure 1). Diagrams Timing Marks and Indicators: Diagrams TIMING MARK 1981-85 5.2L & 5.9L Recall 84V047000: Master Cylinder Defect Brake Master Cylinder: All Technical Service Bulletins Recall 84V047000: Master Cylinder Defect PISTON WITHIN MASTER CYLINDER MAY DEVELOP A SEAL LEAKAGE. THIS DEFECT MAY RESULT IN INTERMITTENT LOSS OF FRONT WHEEL BRAKES. DEFECTIVE MASTER CYLINDERS WILL BE REPLACED FREE OF CHARGE. VEHICLE DESCRIPTION: LIGHT TRUCKS. SYSTEM: SERVICE BRAKES; MASTER CYLINDER. CONSEQUENCES OF DEFECT: MALFUNCTION OF THE FRONT WHEEL BRAKES COULD RESULT IN AN ACCIDENT AND PERSONAL INJURY, PARTICULARLY IN SITUATIONS REQUIRING A MINIMUM STOPPING DISTANCE. NOTE: FRONT WHEEL BRAKE FAILURE SHOULD BE PRECEDED BY ACTIVATION OF AN INSTRUMENT PANEL WARNING LIGHT. 1984 DODGE TRUCK B150 1984 DODGE TRUCK B250 1984 DODGE TRUCK B350 1984 DODGE TRUCK D1 1984 DODGE TRUCK D2 1984 DODGE TRUCK RAMCHARGER 1984 DODGE TRUCK W1 1984 DODGE TRUCK W2 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. Page 3401 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 support bracket. Install by attaching relay to the instrument panel support bracket and connecting the wires to the relay. Connect the battery negative terminal and test the system for proper operation. Page 3683 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 Page 3916 Fig. 7 Ash Tray, Cargo, Glove Box & Map Lamp Wiring Circuits. 1983-84 Page 523 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 Page 2160 FIGURE 3D - BODY WIRING Page 535 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. Page 1896 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 Page 341 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. Page 2256 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 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: 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. Page 3770 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). Page 3535 Fig. 6 Speed control wiring diagram. 1985 Conventional Cabs & Ramcharger Page 2775 Fig 1 Eleven Inch Brake Assembly 10. Using Tool C-3785, or equivalent, install spring over anchor. (Be sure cable guide remains flat against shoe web and that secondary spring overlaps primary). 11. Using pliers, squeeze ends of spring loops (around anchor) until parallel. 12. Install adjusting star wheel assembly between primary and secondary shoes, with star wheel next to secondary shoe. - The left star wheel adjusting stud end is stamped "L" (indicating its position on the vehicle) and the star wheel is cadmium plated. - The right star wheel is black and the adjusting stud end is stamped "R". Page 1250 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine 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. Page 2007 FIGURE 3-A Page 3625 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS 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: 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 Page 157 Ignition Control Module: Mechanical Specifications Part No. Spark Advance Test Electronic EGR Time Delay Electronic Throttle Control 4289075 44 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289077 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289086 44 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289094 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289304 39 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289308 43 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289310 42 +/- 4 deg at 2000 rpm 20 min 20 sec 4289324 20 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289326 21 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289351 39 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289352 43 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289356 20 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289357 21 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289364 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. Page 1132 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 Page 3215 11. Install new cover and screws with "O" rings, PN 4411998. 12. Torque the cover screws to 40-50 inch pounds (4.5 - 5.6 N-m). 13. Check the hubs for locking/unlocking. POLICY: Information only Page 2345 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. Page 2277 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Page 806 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. Page 3045 Fig. 28 Engine Compartment Electrical Spark Advance (Less Feedback Carburetor, Part 1 of 3) Wiring Circuit. 1983-84 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. Page 2188 FIGURE 3-A Page 2338 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. Page 3313 FIGURE 1 3. Pull the antenna plug out of the ferrule about 1/8" (Figure 1). If the radio starts playing, remove radio and send to a warranty repair station. Mark the repair order: ANTENNA FERRULE PROBLEM If the radio does not play when the antenna plug was pulled out 1/8", substitute a known good antenna to determine if the car antenna is defective. POLICY: Information only Page 3824 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). Page 3601 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. 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. Page 3710 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 Page 2885 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. 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. Page 1530 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. Page 10 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 support bracket. Install by attaching relay to the instrument panel support bracket and connecting the wires to the relay. Connect the battery negative terminal and test the system for proper operation. Page 1945 (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 Page 1532 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). Page 211 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. Description and Operation Catalytic Converter: Description and Operation Fig. 12 Typical catalytic converter Removal & Installation Crankshaft Position Sensor: Service and Repair 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. Page 1641 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. Page 1119 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). Page 3833 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. Diagram Information and Instructions Engine 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. 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. Page 3619 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. Page 1186 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 Page 2622 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. Page 2282 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. Page 2175 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. Locations Detonation (Knock) Sensor: Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Locations Distributor Vacuum Control: Locations Orifice Spark Advance Control (OSAC) Valve Location. In Air Cleaner Housing Applicable to: V8 Engine Page 278 FIGURE 3C - BODY WIRING Page 277 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 Page 3865 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 Page 2250 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). Page 2057 NOTE: DO NOT REUSE FUEL HOSE CLAMPS. 8. Start engine and inspect for leaks. FIGURE 2 Type the Authorized Modification Label as shown in Figure 2. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 14-47-84-90..........................0.2 Hrs. FAILURE CODE: 68 - Noisy Page 72 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. Locations Spark Control Relay: Locations Electronic Ignition System Components On Firewall Page 1372 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. 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, Locations Air Diverter Valve: Locations LH Side Of Engine Applicable to: 1984-85 V8 Engine Page 2167 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. Diagram Information and Instructions EGR 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. 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 ) 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. Page 534 FIGURE 3-A Page 2137 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 Specifications Page 1003 TIMING MARK 1981-90 Some 5.2L & 5.9L Page 1327 Air/Fuel Mixture: Adjustments Idle Mixture (Propane Method) Fig. 1 Propane enrichment specification chart EXC. 1985 MODELS 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 or limiter 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. 5. Disconnect and plug vacuum hose at EGR valve, ESA computer and distributor, as required. 6. On models equipped with carburetor ground switch, connect jumper wire between switch and ground. 7. On models not equipped with Spark Control Computer (SCC), disconnect and plug vacuum hose from carburetor at heated air temperature sensor and OSAC valve, if equipped, then remove air cleaner. 8. On models with SCC, air cleaner cannot be removed but may be propped up. 9. Disconnect vacuum hose from heated air door or choke diaphragm, except as listed below, and connect hose from metering valve on enrichment tool to fitting. 10. Remove PCV valve from cylinder head cover and allow to draw underhood air. 11. Disconnect plug control hose at canister. 12. On models equipped with oxygen sensor feedback, disconnect electrical connector from oxygen sensor and ground connector. Remove and plug vacuum hose at vacuum transducer on SCC, then install suitable vacuum pump to vacuum transducer, apply 16 inches of vacuum, and allow engine to run for two minutes. 13. On models without oxygen sensor feedback, allow engine to run for one minute. 14. On all models, 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. 15. With propane flowing, adjust idle speed to specified enriched RPM, Fig. 1, by turning idle speed screw. 16. Adjust metering valve to obtain maximum RPM. If there has been a change in maximum RPM, readjust idle speed screw to specified enriched RPM. 17. Turn off main propane valve and allow engine speed to stabilize. 18. Adjust mixture screws to obtain smoothest idle at specified curb idle RPM, allowing time between adjustments for engine speed to stabilize. 19. 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 15 through 20. 20. When adjustment is correct, turn off both propane valves, stop engine and remove tool. 21. Install concealment plug, if equipped, then perform ``Curb Idle Speed, Adjust'' and ``Fast Idle Speed, Adjust'' procedure. Page 3769 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) Page 1891 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. Page 1901 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. Page 3008 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. Page 3668 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). 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 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 Page 1499 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. Engine - High Altitude Conversion Package Air/Fuel Mixture: Technical Service Bulletins Engine - High Altitude Conversion Package Models 1984 318-4V & 360-4V Heavy Duty Truck Subject High Altitude Conversion Package & Adjustment for Improved Engine Performance Index EMISSIONS Date 11/12/84 No. 25-05-84 P-5036C A package is now available to accommodate a customer who wishes to convert his 1984 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 1984 non-altitude equipped engine families in service at altitudes above 4,000 feet above sea level.. CONVERSION INSTRUCTIONS Sea Level to Altitude IMPORTANT: IN SOME OF THE CONVERSION PROCEDURES YOU WILL BE REQUIRED TO INSTALL A NEW VEHICLE EMISSION CONTROL INFORMATION UPDATE (VECIU) LABEL, PN 4275084. FIGURE 1 THIS LABEL HAS TWO AREAS THAT ARE IMPACT IMPRINTABLE WITH A TYPEWRITER (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, THEN JUST TYPE IN THE NEW SPECIFICATION AFTER THE SUBJECT OPERATION. IF YOU ARE ASKED TO REFER TO THE ORIGINAL VECI Page 2988 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. Page 3688 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. Page 2144 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 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. Page 2170 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. Page 533 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. Page 3116 Fig. 18 Tilt wheel steering column exploded view. Exc. front wheel drive Mini-Vans/Wagons Page 3111 Fig. 44 Tilt Wheel Wiring Circuit. 1983-84 Page 137 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 Page 593 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. Page 227 Fig. 3 Speed control wiring diagram. 1981-84 Ramcharger, Trail Duster & Conventional Cabs Page 968 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. Page 1658 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). 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. Page 2041 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. Page 3653 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. Page 3458 Fig. 3 Speed control wiring diagram. 1981-84 Ramcharger, Trail Duster & Conventional Cabs Page 2328 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). Page 595 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). Page 1638 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. Page 3102 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. Page 2283 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 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. Page 3507 Fig. 8 Speed control wiring diagram. 1986-87 Conventional Cabs & Ramchargers Specifications Page 3654 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. 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. Specifications Page 1507 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). Page 2503 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. 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: Page 1145 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Locations Air Injection Check Valve: Locations Upper LH Side Of Engine Applicable to: 1984-85 V8 Engine Page 1033 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 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. Page 544 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 Page 1622 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. Page 1174 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. 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. Locations Stop Lamp Switch: Locations On Brake Pedal 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. Page 2853 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. Locations Clutch Switch: Locations On Clutch Pedal Service and Repair 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. Page 2447 Crankshaft Position Sensor: Service and Repair 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. Page 119 FIGURE 3D - BODY WIRING 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. Service and Repair 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. Page 39 FIGURE 3-A Page 2273 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. Page 2107 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. Page 2211 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 Page 2151 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 Page 2085 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 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. Page 2735 Fig. 14 Tools positioned to press outer bearing onto hub. 44 FBJ Units w/disc brakes. Models w/full time 4WD Fig. 15 Forming a seal on bearing retainer face. 44 FBJ Units w/disc brakes. Models w/full time 4WD Page 992 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 Page 2298 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). Master Cylinder Bleeding Brake Master Cylinder: Service and Repair Master Cylinder Bleeding Bench Bleeding 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. 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 Page 1630 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Page 73 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. Page 3137 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. Page 1376 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 Page 1258 Crankshaft Position Sensor: Service and Repair 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. 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: Page 537 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 Page 3557 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. Page 1677 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 Page 4051 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. 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. Description and Operation 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. Diagram Information and Instructions Multiple Junction Connector: 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. Page 1623 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 Page 2134 FIGURE 3-A Page 1138 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 Locations Spark Control Relay: Locations Electronic Ignition System Components On Firewall Page 3323 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. Page 1492 *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 Page 128 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 Page 2093 FIGURE 3D - BODY WIRING Page 2961 Fig. 5 Charging system diagnosis chart Page 609 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). Page 3525 Fig. 8 Speed control wiring diagram. 1986-87 Conventional Cabs & Ramchargers Page 588 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) Locations Clutch Switch: Locations On Clutch Pedal Page 3488 Fig. 7 Speed control wiring diagram. 1985 rear wheel drive Ram Van & Wagons Page 2279 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. 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. Locations Vacuum Amplifier: Locations Exhaust Gas Recirculation (EGR) System Components Upper RH Side Of Engine Page 97 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). Page 2022 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 Page 1190 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). Page 3169 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. Page 3146 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 Diagram Information and Instructions Oil Pressure Warning Lamp/Indicator: 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. Page 1629 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). Page 1037 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. Page 3490 Fig. 9 Speed control wiring diagram. 1986 rear wheel drive Ram Van & Wagons Page 2320 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). Page 287 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. Page 2708 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. Page 1193 FIGURE 3C - BODY WIRING Page 1966 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. Page 337 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). 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. Page 3394 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). Page 1929 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 Page 96 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 Page 1506 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 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. Page 3461 Fig. 6 Speed control wiring diagram. 1985 Conventional Cabs & Ramcharger Locations Distributor Vacuum Control: Locations Orifice Spark Advance Control (OSAC) Valve Location. In Air Cleaner Housing Applicable to: V8 Engine Page 3927 Fig. 7 Ash Tray, Cargo, Glove Box & Map Lamp Wiring Circuits. 1983-84 Page 2543 Fluid - Differential: Specifications Differential Above 90°F (32°C), 140, 80W-140, 85W-140; above -10°F (-23°C), 90, 80W-90, 80W-140, 85W140; below -10°F (-23°C), 75W, 80W, 75W-90, 80W-140 REAR: Standard................................................................................................................................... ..........................................................................GL-5 Anti-Spin, Limited-Slip, Power-Loc, Sure-Grip, Trac-Loc.......................................................................................................................................90 GL-5* FRONT: 4 x 4....................................................................................................................................... .........................................................................GL-5 CAPACITY, Refill: Front: 4-wheel drive ex.Spicer 60F....................................................................................................................................... ................1.7 Liters 3.5 Pints Spicer 70.............................................................................................................................................. ..................................................3.1 Liters 6.5 Pints Rear: Spicer 60, 60 HD........................................................................................................................ ................................................2.8 Liters 6.0 Pints Spicer 70.............................................................................................................................................. ..................................................3.1 Liters 6.5 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 Page 971 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 Page 3813 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. Page 1724 Crankshaft Position Sensor: Service and Repair Distributor Assembly 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. Page 3276 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. Page 2184 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. Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Balancer Bolt Torque Balancer Bolt Torque Vibration Damper Or Pulley 100 ft.lb Electronic Control Unit Engine Control Module: Locations Electronic Control Unit Electronic Ignition System Components On Firewall Page 1965 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. Page 2244 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). Page 943 Air/Fuel Mixture: Adjustments Idle Mixture (Propane Method) Fig. 1 Propane enrichment specification chart EXC. 1985 MODELS 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 or limiter 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. 5. Disconnect and plug vacuum hose at EGR valve, ESA computer and distributor, as required. 6. On models equipped with carburetor ground switch, connect jumper wire between switch and ground. 7. On models not equipped with Spark Control Computer (SCC), disconnect and plug vacuum hose from carburetor at heated air temperature sensor and OSAC valve, if equipped, then remove air cleaner. 8. On models with SCC, air cleaner cannot be removed but may be propped up. 9. Disconnect vacuum hose from heated air door or choke diaphragm, except as listed below, and connect hose from metering valve on enrichment tool to fitting. 10. Remove PCV valve from cylinder head cover and allow to draw underhood air. 11. Disconnect plug control hose at canister. 12. On models equipped with oxygen sensor feedback, disconnect electrical connector from oxygen sensor and ground connector. Remove and plug vacuum hose at vacuum transducer on SCC, then install suitable vacuum pump to vacuum transducer, apply 16 inches of vacuum, and allow engine to run for two minutes. 13. On models without oxygen sensor feedback, allow engine to run for one minute. 14. On all models, 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. 15. With propane flowing, adjust idle speed to specified enriched RPM, Fig. 1, by turning idle speed screw. 16. Adjust metering valve to obtain maximum RPM. If there has been a change in maximum RPM, readjust idle speed screw to specified enriched RPM. 17. Turn off main propane valve and allow engine speed to stabilize. 18. Adjust mixture screws to obtain smoothest idle at specified curb idle RPM, allowing time between adjustments for engine speed to stabilize. 19. 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 15 through 20. 20. When adjustment is correct, turn off both propane valves, stop engine and remove tool. 21. Install concealment plug, if equipped, then perform ``Curb Idle Speed, Adjust'' and ``Fast Idle Speed, Adjust'' procedure. Electronic Control Unit Engine Control Module: Locations Electronic Control Unit Electronic Ignition System Components On Firewall Page 1147 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 Page 3664 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 Page 1881 Air/Fuel Mixture: Adjustments Idle Mixture (Propane Method) Fig. 1 Propane enrichment specification chart EXC. 1985 MODELS 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 or limiter 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. 5. Disconnect and plug vacuum hose at EGR valve, ESA computer and distributor, as required. 6. On models equipped with carburetor ground switch, connect jumper wire between switch and ground. 7. On models not equipped with Spark Control Computer (SCC), disconnect and plug vacuum hose from carburetor at heated air temperature sensor and OSAC valve, if equipped, then remove air cleaner. 8. On models with SCC, air cleaner cannot be removed but may be propped up. 9. Disconnect vacuum hose from heated air door or choke diaphragm, except as listed below, and connect hose from metering valve on enrichment tool to fitting. 10. Remove PCV valve from cylinder head cover and allow to draw underhood air. 11. Disconnect plug control hose at canister. 12. On models equipped with oxygen sensor feedback, disconnect electrical connector from oxygen sensor and ground connector. Remove and plug vacuum hose at vacuum transducer on SCC, then install suitable vacuum pump to vacuum transducer, apply 16 inches of vacuum, and allow engine to run for two minutes. 13. On models without oxygen sensor feedback, allow engine to run for one minute. 14. On all models, 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. 15. With propane flowing, adjust idle speed to specified enriched RPM, Fig. 1, by turning idle speed screw. 16. Adjust metering valve to obtain maximum RPM. If there has been a change in maximum RPM, readjust idle speed screw to specified enriched RPM. 17. Turn off main propane valve and allow engine speed to stabilize. 18. Adjust mixture screws to obtain smoothest idle at specified curb idle RPM, allowing time between adjustments for engine speed to stabilize. 19. 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 15 through 20. 20. When adjustment is correct, turn off both propane valves, stop engine and remove tool. 21. Install concealment plug, if equipped, then perform ``Curb Idle Speed, Adjust'' and ``Fast Idle Speed, Adjust'' procedure. Page 2162 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). Page 1536 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. Specifications Page 1682 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). Page 789 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. 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 Page 3691 *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 Page 3771 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. Page 316 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 Page 3834 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 Page 900 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. Page 296 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* Page 304 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. Page 516 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. Removal and Installation Brake Pad: Service and Repair Removal and Installation Removal Fig 1 Disc Brake Assembly (Rear View) 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 5 Removing Or Installing Caliper 5. Remove caliper from disc by slowly sliding caliper assembly out and away from disc. Page 1604 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). Page 3800 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). Page 1933 (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). Paint - Variance Program Paint: 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 Page 3416 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.) 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 Page 2066 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. Page 3988 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. Page 1459 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 Recall 84V047000: Master Cylinder Defect Brake Master Cylinder: Recalls Recall 84V047000: Master Cylinder Defect PISTON WITHIN MASTER CYLINDER MAY DEVELOP A SEAL LEAKAGE. THIS DEFECT MAY RESULT IN INTERMITTENT LOSS OF FRONT WHEEL BRAKES. DEFECTIVE MASTER CYLINDERS WILL BE REPLACED FREE OF CHARGE. VEHICLE DESCRIPTION: LIGHT TRUCKS. SYSTEM: SERVICE BRAKES; MASTER CYLINDER. CONSEQUENCES OF DEFECT: MALFUNCTION OF THE FRONT WHEEL BRAKES COULD RESULT IN AN ACCIDENT AND PERSONAL INJURY, PARTICULARLY IN SITUATIONS REQUIRING A MINIMUM STOPPING DISTANCE. NOTE: FRONT WHEEL BRAKE FAILURE SHOULD BE PRECEDED BY ACTIVATION OF AN INSTRUMENT PANEL WARNING LIGHT. 1984 DODGE TRUCK B150 1984 DODGE TRUCK B250 1984 DODGE TRUCK B350 1984 DODGE TRUCK D1 1984 DODGE TRUCK D2 1984 DODGE TRUCK RAMCHARGER 1984 DODGE TRUCK W1 1984 DODGE TRUCK W2 Page 2560 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. Page 3543 Fig. 3 Speed control wiring diagram. 1981-84 Ramcharger, Trail Duster & Conventional Cabs Page 3453 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 Locations Detonation (Knock) Sensor: Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Page 4025 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. Page 3616 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. Page 126 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. Page 599 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 Page 3209 11. Install new cover and screws with "O" rings, PN 4411998. 12. Torque the cover screws to 40-50 inch pounds (4.5 - 5.6 N-m). 13. Check the hubs for locking/unlocking. POLICY: Information only Page 587 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. Page 1713 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Page 3281 Refrigerant: Fluid Type Specifications A/C Refrigerant Specifications A/C Refrigerant Specifications Refrigerant Types R-12 Page 4045 Power Window Switch: Testing and Inspection Remove both power window switches from their trim panels and remove the wiring harness from the back of each switch. Turn the ignition switch to the "run" position. Check for power and ground by connecting a test light between the TN and WT wires at the left switch harness and between the TN wire and ground of the right switch harness. If the test light does not illuminate or is dim, check the circuit breaker, relay, and wiring to the switch. Power Window Switch Test To test left switch function, connect jumper wires as shown to the right switch harness. 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 window motors do not operate properly, the window motors or wiring may be defective. To test the right switch function, connect a jumper wire between the WT and VT wires of the left window switch. Now connect a jumper wire between the TN and PK wires of the right window switch. The right window should move down. Disconnect the jumper wires and connect a jumper wire between the WT and PK wires at the left window switch. Now connect a jumper wire between the TN and VT wires of the right window switch. The right window should go up. If the window operates properly, the right window switch is defective. If the window does not operate properly, the window motor or wiring may be defective. Diagram Information and Instructions EGR 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. 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. 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. Page 2325 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. Locations Trailer Lamps: Locations Circuit Location Amps Headlights.....................Integral With Switch..............20 Trailer Towing................Fuse Panel.........................6 Windshield Wipers.............Integral With Switch..............20 Page 1692 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. Page 2878 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. Page 1469 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). Page 2025 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 Page 2106 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 Page 3594 FIGURE 3-A Page 395 Crankshaft Position Sensor: Service and Repair 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. 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: Page 127 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. Page 4018 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 support bracket. Install by attaching relay to the instrument panel support bracket and connecting the wires to the relay. Connect the battery negative terminal and test the system for proper operation. Page 120 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. Page 2795 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. 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 Page 259 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. Page 1488 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 Page 3825 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. Page 295 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. Page 1135 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). Page 3621 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. Page 1448 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. Page 3772 FIGURE 3-A 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). Specifications Page 2716 Fig. 7 Bending Outboard Pad Retaining Flange NOTE: No free play between brake shoe flanges and caliper fingers should exist (which might cause brake shoe rattle). Fig 11 Attaching Shoe To Caliper Fingers With C-Clamp - 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. Page 3413 Paint: Technical Service Bulletins Paint - Codes/Cross References Models All 1984 Domestic & Import Passenger Car & Truck Subject 1984 Standard Colors Index BODY Date Sept, 1983 (current) No. 23-13-83 Attached sheets list the Chrysler paint codes which are located on the vehicle body code plate. For location of the code plate see service manual. A sample domestic passenger car plate is enclosed for reference only. First three spaces on second line designates whether vehicle is monotone, two-tone car, or two-tone truck. APA - Monotone APB - Two-Tone Car APC - Two-Tone Truck Page 3867 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. 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. Specifications Page 1150 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 Page 3474 Fig. 7 Speed control wiring diagram. 1985 rear wheel drive Ram Van & Wagons 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. Radio - Speaker Noise When Warning Buzzers Are ON Seat Belt Reminder Buzzer: Customer Interest Radio - Speaker Noise When Warning Buzzers Are ON Models 1984 Vehicles Equipped With Standard AM/FM (Sales Code RAL) Radio Subject Radio Noise From Warning Buzzer on AM Band Index ELECTRICAL Date November 23, 1984 No.. 08-26-84 P-4992 SYMPTOM/CONDITION Subject vehicles may exhibit excessive noise on the AM band when seat belt, headlamp on, key in warning buzzer is operated. REPAIR PROCEDURE Replace Warning Buzzer, PN 3747751, (grey case) with new Suppressed Warning Buzzer, PN 4221730, (green case). Verify operation of all buzzer functions. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Refer to Labor Operation Time Schedule for Labor Operation and Time Allowance. Page 1597 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) Page 2232 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 Differential Gear/Axle Shaft - C Lock Revision Carrier Side Gears: Technical Service Bulletins Differential Gear/Axle Shaft - C Lock Revision Models 1984 Domestic Trucks, Vans & Wagons Equipped With 9-1/4 Rear Axle Subject Revised "C" Lock, Differential Gear & Axle Shaft Index REAR AXLE Date November 5, 1984 No. 03-02-84 P-4912-C FIGURE 1 FIGURE 2 A revised rear axle assembly with larger axle "C" locks entered production on February 12, 1984 (Figure 1). The corresponding axle shafts and differential side gears were changed to accommodate the larger "C" locks. Axle assemblies built with the larger "C" locks and components are identified with the letter "X" stamped as shown in Figure 2. CAUTION: THE LARGER "C" LOCKS AND CORRESPONDING AXLE SHAFTS AND DIFFERENTIAL GEARS MUST NOT BE INTERCHANGED WITH Page 2027 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). Page 1305 Crankshaft Position Sensor: Service and Repair 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. 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. Page 1606 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. Page 2102 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 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. Page 2008 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. Page 2074 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. Page 1963 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. Locations Cruise Control Module: Locations Speed Control System Components LH Side Of Engine Compartment Wheel Cover - Loose/Falls Off Wheel Cover: Customer Interest Wheel Cover - Loose/Falls Off Models 1984 D, W & B 250 - 350 Dodge Pick-Up Trucks & Van/Wagons Subject Wheel Cover Retention With 16.5 x 6.75 H.D. Wheels Index WHEELS & TIRES Date November 12, 1984 No. 22-01-84 P-4993-C SYMPTOM/CONDITION A small number of subject vehicles may exhibit a condition of lack of wheel cover/hub cap retension on one or more of the wheels. The wheel covers/hub caps may not grip the embossment on the wheel, thus the cover will not stay on. This occurs primarily during installation at new vehicle pre-delivery. If the above condition occurs, the wheel must be replaced. PARTS REQUIRED 16.5 x 6.75 H.D. Wheel PN 4284446 NOTE: REPLACED WHEELS MUST BE RETURNED TO THE MATERIAL RETURN CENTER. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 22-40-01-02 . . . . . . . . . . . 0.6 Hrs. FAILURE CODE: HR - Improper Retention Page 1600 FIGURE 3-A Page 2617 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. Page 2190 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. 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 Specifications 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". Page 3881 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. 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. Page 2321 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). Page 3804 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 Page 678 Circuit Breaker: Service and Repair Door Lock And Power Window Circuit Breaker And Relays Location Disconnect the battery negative terminal. Remove the two wires from the circuit breaker and remove the circuit breaker from its mounting clip. Install new circuit breaker to the mounting clip and connect the two wires. Connect the battery negative terminal and test power door lock system for proper operation. Page 1904 (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 Page 3521 Fig. 4 Speed control wiring diagram. 1982-84 Rampage & 1983 Scamp Page 2269 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 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 Engine - Valve Train Noise Rocker Arm Assembly: All Technical Service Bulletins Engine - Valve Train Noise Models 1984 Rear Wheel Drive Passenger Car Equipped W/318 Engine; 1984 Rear Wheel Drive Truck & Vans Equipped W/318 or 360 Engine Subject Valve Rocker Arm Breakage Index ENGINE Date December 21, 1984 No.. 09-11-84 SYMPTOM/CONDITION Noise in valve train. DIAGNOSIS Remove valve cover and inspect rocker arms for breakage in the push rod area. The push rod may have penetrated the rocker arm. PARTS REQUIRED Passenger Car & Truck 8 - Rocker Arm PN 4100774 8 - Rocker Arm PN 4100775 REPAIR PROCEDURE When a rocker arm is found to have failed in the above manner in the subject model engines, it is necessary to replace all 16 rocker arms and inspect the push rods. 1. Remove valve covers. 2. Remove all rocker arms and replace with new ones. 3. Inspect push rods and replace as necessary. 4. Reinstall rocker shafts and torque screws to 25 foot pounds (34 N-m). 5. Replace valve cover gaskets and reinstall valve covers. Tighten valve cover screws to 80 inch pounds (9 N-m). POLICY: Information only 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. Page 1435 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. Page 1547 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 Page 1159 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 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. Page 2153 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. Page 1993 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 Page 3550 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. Page 2254 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 Page 3527 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. Page 348 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. Page 3141 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 Page 1152 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 Page 314 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. Page 2454 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. Specifications Page 1203 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. Page 2230 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* Page 3153 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 Bosch & Nippondenso Alternators Voltage Regulator: Testing and Inspection Bosch & Nippondenso Alternators Voltage regulation is controlled by the SMEC unit. Page 2222 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. Page 256 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. Page 56 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 Page 1166 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) Page 3634 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. Page 1946 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. Locations Detonation (Knock) Sensor: Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Page 229 Fig. 5 Speed control wiring diagram. 1984 Mini-Vans/Wagons (1985 similar) Page 1897 (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. Page 3869 *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 Page 1473 FIGURE 3C - BODY WIRING Page 1436 Crankshaft Position Sensor: Service and Repair Distributor Assembly 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. 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. Page 1559 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. Page 3815 *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 Specifications 4 Barrel Carburetor Page 2337 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 Page 1654 FIGURE 3-A Page 375 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. Page 2833 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. Page 3160 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 Page 2073 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. Page 2217 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). Page 2855 Brake Master Cylinder: Adjustments Not adjustable. Page 1519 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 Page 3134 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. Page 444 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. Page 1631 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Page 136 *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 Page 4017 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. Page 3795 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 Page 3735 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. 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: Page 3984 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. Page 4024 Power Window Switch: Service and Repair Door Components Page 1652 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). Page 1367 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. Page 386 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Page 3794 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. Page 8 Power Door Lock Relay: Locations Electric Door Lock Relays Electric Door Lock Relay Location. Behind LH Side Of I/P Applicable to: 1981-84 Page 3424 Power Door Lock Relay: Locations Electric Door Lock Relays Electric Door Lock Relay Location. Behind LH Side Of I/P Applicable to: 1981-84 Page 258 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). 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: Page 263 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 Locations Cruise Control Module: Locations Speed Control System Components LH Side Of Engine Compartment Page 1890 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 Locations Oil Pressure Sender: Locations Engine Mounted Switches & Sensors. Top Of Engine Applicable to: V8 Engine Page 59 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). Page 3779 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. Fuel Pressure Regulator - Clicking/Tapping Noise Fuel Pressure Regulator: All Technical Service Bulletins Fuel Pressure Regulator Clicking/Tapping Noise Models 1984 Domestic Vehicles Equipped With Turbo Charged Engine Subject Pressure Regulator Clicking Noise Index FUEL Date December 3, 1984 No. 14-47-84 P-5297-C SYMPTOM/CONDITION Noises identified as "clicking", "tapping", or "rattling" may be caused by the fuel pressure regulator. Pulsing from the regulator can be transmitted into the fuel tubes and thus transmitted into the passenger compartment. This noise is most noticeable at idle or just off idle. PARTS REQUIRED Damper Package PN 4203640 Consists of: 1 - Damper & Hose Assembly PN 4203639 2 - Clamps PN 6500650 Must be ordered separately: 1 - Authorized Modification Label PN 4275086 REPAIR PROCEDURE 1. Bleed off fuel pressure from system.. 2. Remove outlet hose from the fuel pressure regulator. 3. Remove nut attaching regulator to regulator bracket and save for reassembly. Page 2322 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. Page 286 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 Page 1195 FIGURE 3D - BODY WIRING Page 2859 Brake Master Cylinder: Service and Repair Master Cylinder Replacement Removal 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. Installation Page 2762 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 Page 3078 Fig. 28 Engine Compartment Electrical Spark Advance (Less Feedback Carburetor, Part 2 of 3) Wiring Circuit. 1983-84 Page 1951 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. Page 394 Crankshaft Position Sensor: Service and Repair 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. 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. 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. Page 2228 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. Page 1991 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. Page 79 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. Page 2308 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 Page 2744 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. 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. 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. Page 3776 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). Page 2248 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. Page 3079 Fig. 28 Engine Compartment Electrical Spark Advance (Less Feedback Carburetor, Part 3 of 3) Wiring Circuit. 1983-84 Page 1175 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. Page 3811 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 Page 2186 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). Page 3329 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. Page 1673 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. Service and Repair 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. Page 1477 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). Page 1111 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. Page 3046 Fig. 28 Engine Compartment Electrical Spark Advance (Less Feedback Carburetor, Part 2 of 3) Wiring Circuit. 1983-84 Specifications 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 Page 541 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. 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. Diagram Information and Instructions Oil Pressure Gauge: 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. Page 133 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. Page 2309 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 Page 1491 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* Page 1636 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. Page 3803 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Page 1117 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. Page 3407 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). Page 55 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 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. Page 483 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. 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. 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. Diagram Information and Instructions Engine 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. Page 2334 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. Page 2806 - The vehicle may pull to one side or the other if this is not done. Page 1134 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. 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 Page 1373 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. Page 3546 Fig. 6 Speed control wiring diagram. 1985 Conventional Cabs & Ramcharger Page 3368 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 Page 2011 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). Page 2396 Crankshaft Position Sensor: Service and Repair Distributor Assembly 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. Page 3038 Fig. 3 Bulkhead Connector (40 Way). 1983-84 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 Page 966 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). Page 132 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 Page 3498 Fig. 16 Speed control cable installation. 1980-87 Ramcharger, Trail Duster & Conventional Cabs Page 2777 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. Page 2009 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. 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. 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, 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: Service and Repair 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. Page 1484 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 Page 1602 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. Page 2555 SMALLER "C" LOCK AND COMPONENT PARTS EXCEPT AS ASSEMBLIES. Service procedures remain the same as 1984 9-1/4 axles. Small "C" Lock Large "C" Lock Axle Shaft 4.50" B.C. PN 3723824 PN 4137428 Axle Shaft 5.50" B.C. PN 4037726 PN 4137429 Differential Side Gear PN 4137319 PN 4137675 "C" Lock PN 2852883 PN 4137669 Sure Grip Partial PN 3723691 PN 4137425 Assembly POLICY: Information only Page 3007 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. Page 205 Fig. 4 Speed control wiring diagram. 1982-84 Rampage & 1983 Scamp Page 2032 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. 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 Radio - Speaker Noise When Warning Buzzers Are ON Seat Belt Reminder Buzzer: All Technical Service Bulletins Radio - Speaker Noise When Warning Buzzers Are ON Models 1984 Vehicles Equipped With Standard AM/FM (Sales Code RAL) Radio Subject Radio Noise From Warning Buzzer on AM Band Index ELECTRICAL Date November 23, 1984 No.. 08-26-84 P-4992 SYMPTOM/CONDITION Subject vehicles may exhibit excessive noise on the AM band when seat belt, headlamp on, key in warning buzzer is operated. REPAIR PROCEDURE Replace Warning Buzzer, PN 3747751, (grey case) with new Suppressed Warning Buzzer, PN 4221730, (green case). Verify operation of all buzzer functions. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Refer to Labor Operation Time Schedule for Labor Operation and Time Allowance. Page 767 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. Page 2116 FIGURE 1 4. Place damper assembly with attached bracket onto outlet end of pressure regulator and line up with locating notch (Figure 1) 5. Replace nut onto pressure regulator outlet nipple and torque to 100 inch pounds (+/-) 20 inch pounds. 6. Attach free end of formed hose onto pressure regulator with the supplied clamp and torque to 8-13 inch pounds. FIGURE 1 7. Return hose, originally attached to pressure regulator, should be reassembled onto outlet nipple of damper with remaining clamp. Torque to 8-13 inch pounds (Figure 1). Page 2479 Fig. 31 Four Wheel Drive Indicator Lamp Wiring Circuit. 1983-84 Page 3846 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). 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 Page 882 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. Locations Intake Air Temperature Switch: Locations Engine Mounted Switches & Sensors. Upper RH Side Of Engine Page 1356 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 Page 600 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 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. Page 3099 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 Page 3768 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. Page 1350 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). Page 2015 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 Page 2578 11. Install new cover and screws with "O" rings, PN 4411998. 12. Torque the cover screws to 40-50 inch pounds (4.5 - 5.6 N-m). 13. Check the hubs for locking/unlocking. POLICY: Information only Page 3851 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. Page 2187 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. Page 3567 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. Page 2773 6. Disengage primary and secondary shoes and remove adjusting star wheel assembly from shoes. 7. Remove brake shoe retainers, springs and nails -- using Tool C-4070 or equivalent,, and remove from support. 8. Remove parking brake lever from secondary shoes. Remove shoes. 9. Disengage parking brake lever from parking brake cable. Installation For additional information see Notes, Warnings, and Hints. 1. Lubricate the six shoe tab contact pads on support plate with a thin film of MOPAR Multi-Purpose Lubricant, Part number 4318063 or equivalent. 2. Engage parking brake lever with cable. Install parking brake lever into rectangular hole of secondary brake shoe. 3. Slide secondary shoe against support plate, at the same time engage shoe web with push rod and against anchor. Page 98 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. Page 289 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 Page 1527 FIGURE 3C - BODY WIRING Page 180 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). Page 1895 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. Page 2688 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. Page 2826 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. 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 Electrical Specifications Wheel Cover - Loose/Falls Off Wheel Cover: All Technical Service Bulletins Wheel Cover - Loose/Falls Off Models 1984 D, W & B 250 - 350 Dodge Pick-Up Trucks & Van/Wagons Subject Wheel Cover Retention With 16.5 x 6.75 H.D. Wheels Index WHEELS & TIRES Date November 12, 1984 No. 22-01-84 P-4993-C SYMPTOM/CONDITION A small number of subject vehicles may exhibit a condition of lack of wheel cover/hub cap retension on one or more of the wheels. The wheel covers/hub caps may not grip the embossment on the wheel, thus the cover will not stay on. This occurs primarily during installation at new vehicle pre-delivery. If the above condition occurs, the wheel must be replaced. PARTS REQUIRED 16.5 x 6.75 H.D. Wheel PN 4284446 NOTE: REPLACED WHEELS MUST BE RETURNED TO THE MATERIAL RETURN CENTER. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 22-40-01-02 . . . . . . . . . . . 0.6 Hrs. FAILURE CODE: HR - Improper Retention Page 261 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. Page 2264 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 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. Service and Repair 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. Page 344 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. Page 1799 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. Page 100 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. Page 1621 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). Page 2276 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Locations Mixture Control Solenoid: Locations Engine Mounted Switches & Sensors. On Carburetor Applicable to: V8 Engine 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. Page 3039 Multiple Junction Connector: Electrical Diagrams Fig. 27 Engine Compartment ECU Ignition Wiring Circuit (Part 1 of 3). 1983-84 W/V8 Engine Page 2224 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. Page 1464 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 Page 1776 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. Page 253 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. Page 1212 *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 Page 1685 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Page 1723 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. Page 1445 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. Page 1529 FIGURE 3D - BODY WIRING Page 130 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 Page 1967 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 Page 442 Crankshaft Position Sensor: Service and Repair 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. Page 134 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. Page 3042 Fig. 29 Engine Compartment Electronic Spark Advance (W/Feedback Carburetor, Part 1 of 3) Wiring Circuit. 1983-84 Page 2142 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 Page 3158 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 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: Page 1921 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 Page 220 Fig. 7 Speed control wiring diagram. 1985 rear wheel drive Ram Van & Wagons Steering Column - Coupler Service Steering Column: 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 Page 2177 *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 Page 2245 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. 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. Page 3156 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 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. Page 3062 Fig. 1 Fuse Panel. 1983-84 Specifications Refrigerant Oil: Specifications Capacities Capacities Capacity Viscosity 9-10 oz (US) 500 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. Page 1693 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 Page 338 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Page 3123 Fig. 2 Steering column coupling & shaft adjustment. Motor Home Tilt Column Release Pedal Adjustment 1. Loosen pedal assembly locknut at adjustable mounting bracket assembly. 2. Move column adjusting assembly foot pad rearward, toward the driver, 0.040 inch from center line of rear column adjustable mounting bracket bolt. While holding pedal in this position, tighten nut until column is locked securely. 3. Test operation of column adjusting pedal by depressing and releasing several times. If correctly adjusted, the pedal will return to the approximate position shown. RAMCHARGER, TRAILDUSTER & D/W-100 THRU 400 SERIES Removal 1. Disconnect battery ground cable. 2. On vehicles with automatic transmission column shift, disconnect shift rod at lower end of column by prying grommet out of shift lever. A new grommet should be used whenever the rod is disconnected. 3. Remove coupling roll pin at lower end of column. 4. Disconnect electrical connectors at steering column jacket. 5. Remove steering wheel using a suitable puller. Do not attempt to remove steering wheel using a hammer as damage to the steering column and shaft will result. 6. Remove turn signal lever, then the floor plate to floor pan attaching nuts. 7. On 1980 models, remove cluster bezel. 8. Remove panel lower reinforcement. 9. On 1981 - 87 models, disconnect automatic transmission shift indicator cable from bracket on column. 10. Remove steering column bracket to instrument panel support nuts. 11. Disconnect coupling from steering gear worm shaft and remove steering column. Installation For installation, refer to the "Vans & Wagons Except Front Wheel Drive" procedure, however, torque steering wheel nut to 60 ft lb on 1980 - 82 models or 45 ft lb on 1983 - 87 models. Disassembly/Assembly Page 1465 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 Page 2715 Fig 6 Removing Outboard Shoe 6. Remove outboard shoe (flanges on outboard shoe and retain shoe to caliper) by prying between shoe and caliper fingers. - Support caliper so as not to damage flexible brake hose. Fig 7 Removing Or Installing Inboard Shoe 7. 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. 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 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. Page 978 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. Page 1812 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. 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). Page 1171 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. Page 2048 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. Page 2877 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 Page 862 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. Page 3950 Fig. 36 License Lamp Wiring Circuit. 1983-84 W/Step Hitch Bumper Page 1920 Electric Assist Choke: Locations Thermostatic Choke Coil Electric Assist Choke System Components On Side Of Carburetor Page 1349 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 Page 3092 11. Install seal cup using adapter C-4398-2, and driver C-4398-1. Use a small amount of wheel bearing grease on adapter face to hold cup in position, then drive cup until bottomed in knuckle. Do not remove tool at this time. 12. Apply a 1/4 inch bead of RTV sealer to retainer face on the chamfer. This replaces the O-ring discarded during disassembly. 13. Carefully remove seal installing tool from knuckle bore so that outer axle shaft remains centered. If shaft is moved, ensure that lip seal is still riding inside cup. Correct if necessary. 14. Before installing hub, rotor, retainer and bearing assembly on knuckle, position bearing retainer in hub so that grease fitting is facing forward, if equipped. Use a crossing method and torque retainer plate bolts to 30 ft-lbs. Bearing retainers that have a grease fitting must be positioned on knuckle so that fitting is facing directly forward. 15. Install brake adapter and remove any pry bar from universal joint. 16. Install axle shaft washer and nut. Torque nut to 100 ft-lbs. and continue to tighten nut until next slot in nut aligns with hole in axle shaft. Install cotter pin. 17. Through the access hole in hub, lubricate fitting in bearing retainer with multipurpose grease until grease flows through new inner seal. Seal may be viewed through universal joint area. Spin hub several times and lubricate fitting again. Grease must flow from 1/2 of seal diameter. 18. Replace brake caliper assembly and wheel, then lower vehicle and test operation. MODELS LESS FULL TIME 4WD Removal & Disassembly 1. Remove locking hub assembly, if equipped. 2. Raise vehicle and remove wheel assembly. 3. Remove caliper retainer and anti-rattle spring assemblies. 4. Remove caliper from disc and support caliper to prevent damage to brake line. 5. Remove the inboard brake pad and disc. 6. Remove the caliper adapter from knuckle. 7. Remove the six nuts and washers from spindle to steering knuckle attaching bolts. 8. Remove brake splash shield. 9. Tap spindle lightly with soft faced hammer to free from steering knuckle. 10. Upon removal, examine bronze spacer between needle bearing and shaft joint assembly. If wear is evident, replace. 11. Clamp spindle in vise avoiding bearing carrying surfaces. Remove needle bearing grease seal. 12. Using a suitable puller remover inner axle needle bearings. On 1985-87 models, left spindle does not have needle bearings. 13. Carefully remove axle shaft, axle seal and stone shield, if equipped. 14. Remove the tie rod from the steering knuckle. 15. On the left side only, remove drag link from steering knuckle. 16. On the left side only, remove the nuts and cone washers from steering knuckle arm. Tap the steering knuckle arm to free knuckle. Remove arm. 17. Remove cotter pin from upper ball joint nut. Remove upper and lower ball joint nut. Discard lower nut. 18. Using a brass drift and hammer separate steering knuckle from axle housing yoke. Remove sleeve from upper ball joint using tool C-4169. Discard sleeve. 19. Install steering knuckle in vise and remove snap ring from lower ball joint with suitable snap ring pliers. 20. Using tool C-4212-1 and adapter set C-4288, press lower ball joint from steering knuckle. 21. Reposition tool, and press upper ball joint from steering knuckle. Replace ball joints if any looseness or end play exists. Cleaning & Inspection 1. Clean all parts using a suitable solvent. 2. Blow dry parts using compressed air. 3. Inspect all parts for cracks, wear, chips, burrs and distortion. 4. Replace any parts not suitable for further service. Assembly & Installation 1. Position steering knuckle right side up in a vise. Using tool C-4212-1 and adapter set C-4288, press the lower ball joint into position. 2. Using the same tool and adapter set as above, install the upper ball joint. 3. Install new boots on the ball joints and remove the steering knuckle from the vise. 4. Screw a new sleeve into the upper ball joint yoke leaving two threads showing at the top. 5. Position steering knuckle on axle housing yoke and torque new lower ball joint nut to 80 ft-lbs. 6. Using tool C-4169 and a torque wrench, torque sleeve in upper ball joint to 40 ft-lbs. Install upper ball joint and torque to 100 ft-lbs. Align slot in nut with hole in stud and install cotter pin. Do not loosen to align. 7. On left side only, position steering knuckle arm over studs on steering knuckle. Install cone washers and nuts and torque to 90 ft-lbs. 8. Install drag link on steering knuckle arm and torque to 60 ft-lbs. Install cotter pin. 9. Install the rod end to steering knuckle. Torque nut to 45 ft-lbs. and install cotter pin. 10. Install lip seal on stone shield with lip toward axle shaft spline. 11. On all except 1986-87 left side, carefully insert axle shaft into housing. Avoid damaging differential seal at right side gear or axle shaft seal on left side gear. 12. On 1986-87 left side, proceed as follows: 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 1 Eleven Inch Brake Assembly 1. Remove brake drum. 2. Using Tool C-3785 or equivalent, remove brake shoe return springs. (Note how secondary shoe return spring overlaps primary shoe return spring). For additional information on brake spring removal/installation see Fundamentals and Basics. 3. Slide eye of automatic adjuster cable off anchor and then unhook from adjusting lever. Remove cable assembly, cable guide, and anchor plate. 4. Disengage adjusting lever from spring by sliding forward to clear pivot, then -- working out from under spring -- remove spring from pivot. 5. Remove shoe-to-shoe spring from secondary shoe web and disengage from primary shoe web. Remove spring. Page 3620 FIGURE 3D - BODY WIRING Page 325 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 Page 3812 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. Page 1655 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. Page 207 Fig. 6 Speed control wiring diagram. 1985 Conventional Cabs & Ramcharger Page 912 Fig. 37 Oil Lamp With Gauge Cluster Wiring Circuit. 1984 Page 1486 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 Locations Circuit Breaker: Locations Door Lock And Power Window Circuit Breaker And Relays Location The circuit breaker is located behind the dash panel, to the left of the glove box. Page 331 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 Page 219 Fig. 6 Speed control wiring diagram. 1985 Conventional Cabs & Ramcharger Page 1688 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. Page 1374 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 Page 2813 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. Page 2253 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. Page 2410 Ignition Coil: Locations Electronic Ignition System Components Upper RH Side Of Engine Page 1501 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). Page 3788 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 Page 3845 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. 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: Specifications Page 3387 Door Lock: Electrical Diagrams Fig. 19 Electric Door Lock Wiring Circuit (Cowl Top & Door) Fig. 21 Electric Door Locks & Window Lifts Wiring Circuit (Instrument Panel) Page 634 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 Specifications Compression Check: Specifications Compression Check Specifications Compression Check Specifications Compression Pressure 100 psi At cranking speed, engine temperature normalized, throttle open Maximum Variation 40 psi Page 2141 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. Radio - Speaker Noise When Warning Buzzers Are ON Seat Belt Reminder Buzzer: All Technical Service Bulletins Radio - Speaker Noise When Warning Buzzers Are ON Models 1984 Vehicles Equipped With Standard AM/FM (Sales Code RAL) Radio Subject Radio Noise From Warning Buzzer on AM Band Index ELECTRICAL Date November 23, 1984 No.. 08-26-84 P-4992 SYMPTOM/CONDITION Subject vehicles may exhibit excessive noise on the AM band when seat belt, headlamp on, key in warning buzzer is operated. REPAIR PROCEDURE Replace Warning Buzzer, PN 3747751, (grey case) with new Suppressed Warning Buzzer, PN 4221730, (green case). Verify operation of all buzzer functions. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Refer to Labor Operation Time Schedule for Labor Operation and Time Allowance. Page 465 Fig. 8 Automatic Trans Neutral Star Switch Wiring Circuit. 1983-84 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. 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. Page 3562 Fig. 7 Ash Tray, Cargo, Glove Box & Map Lamp Wiring Circuits. 1983-84 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: Page 3635 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. 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 Page 46 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. Page 2868 - 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. Page 1939 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 Page 3633 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 Page 1449 FIGURE 3-A Page 3142 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. Page 3100 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. Page 1324 LABEL SPECIFICATIONS, TYPE IN ON THE RIGHT HAND SIDE OF THE LABEL "REFER TO ORIGINAL VECI LABEL". IN EVERY CASE WHERE THIS LABEL IS USED, TYPE IN AFTER - AUTHORITY OF TECHNICAL SERVICE BULLETIN #25-05-84, AND YOUR DEALER CODE BELOW. LABEL PN 4275084 IS AVAILABLE FROM PARTS SUPPLY. Conversion Procedure 1. On the 360-4V only, replace the secondary metering jets with PN 4293720. 2. Relieve the tension on the secondary air valve spring by one turn clockwise (both 318 and 360). 3. Adjust the secondary air valve opening to 1/2" (both 318 and 360). 4. Reset basic timing from 4~ to 8~ BTD on 360-4V and from 8~ to 12~ BTD on 318-4V. 5. Reset idle and propane speeds to sea level specifications at altitude. 6. Refer to 1984 Rear Wheel Drive Truck Service Manual for correct procedures for the above adjustments. 7. Type Vehicle Emission Control Information Update Label, PN 4275084, as shown in Figure 1 and install next to or near the original VECI label. NOTE: VEHICLE SHOULD BE RETURNED TO ITS ORIGINAL CONDITION IF DRIVEN AT LOW ALTITUDE. POLICY: Information only Page 2191 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 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. Page 3075 Fig. 29 Engine Compartment Electronic Spark Advance (W/Feedback Carburetor, Part 2 of 3) Wiring Circuit. 1983-84 Page 2278 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 Page 2212 FIGURE 3C - BODY WIRING Page 2169 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 Page 231 Fig. 7 Speed control wiring diagram. 1985 rear wheel drive Ram Van & Wagons Page 2323 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 Wheel Cover - Loose/Falls Off Wheels: Customer Interest Wheel Cover - Loose/Falls Off Models 1984 D, W & B 250 - 350 Dodge Pick-Up Trucks & Van/Wagons Subject Wheel Cover Retention With 16.5 x 6.75 H.D. Wheels Index WHEELS & TIRES Date November 12, 1984 No. 22-01-84 P-4993-C SYMPTOM/CONDITION A small number of subject vehicles may exhibit a condition of lack of wheel cover/hub cap retension on one or more of the wheels. The wheel covers/hub caps may not grip the embossment on the wheel, thus the cover will not stay on. This occurs primarily during installation at new vehicle pre-delivery. If the above condition occurs, the wheel must be replaced. PARTS REQUIRED 16.5 x 6.75 H.D. Wheel PN 4284446 NOTE: REPLACED WHEELS MUST BE RETURNED TO THE MATERIAL RETURN CENTER. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 22-40-01-02 . . . . . . . . . . . 0.6 Hrs. FAILURE CODE: HR - Improper Retention Page 3652 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). Page 1526 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 Page 2757 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. Page 3673 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. Page 1900 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 Page 101 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 Page 1470 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). Page 2117 NOTE: DO NOT REUSE FUEL HOSE CLAMPS. 8. Start engine and inspect for leaks. FIGURE 2 Type the Authorized Modification Label as shown in Figure 2. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 14-47-84-90..........................0.2 Hrs. FAILURE CODE: 68 - Noisy 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. Service and Repair 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 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. Page 2584 11. Install new cover and screws with "O" rings, PN 4411998. 12. Torque the cover screws to 40-50 inch pounds (4.5 - 5.6 N-m). 13. Check the hubs for locking/unlocking. POLICY: Information only Page 964 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. Page 3685 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 Page 2940 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. Page 340 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 Page 2742 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). Service and Repair 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. Page 3524 Fig. 7 Speed control wiring diagram. 1985 rear wheel drive Ram Van & Wagons Specifications Compression Check: Specifications Compression Check Specifications Compression Check Specifications Compression Pressure 100 psi At cranking speed, engine temperature normalized, throttle open Maximum Variation 40 psi Page 519 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. Page 2993 Fig. 8 Automatic Trans Neutral Star Switch Wiring Circuit. 1983-84 Page 2028 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). Page 1490 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. 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. Page 1196 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. Page 1653 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. Page 189 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. Specifications 4 Barrel Carburetor Page 3112 Steering Column: Description and Operation ENERGY ABSORBING STEERING COLUMNS The energy absorbing function of the steering column allows the column to collapse at a controlled rate during a severe collision. The collaPSIng action reduces the possibility of the steering wheel being driven rearward towards the driver. If the driver is thrown forward into the steering wheel, the column can collapse even further at the same controlled rate, thereby reducing the force of impact. Several designs of steering column jackets are used. There is the slip tube design which is held together with plastic inserts or rivets that shear upon impact and allow the column to collapse. And there is the slotted or corrugated mesh design and bellows type design which shorten in length during impact. The shift tube is a two piece design which is held together by injections of plastic that form the interconnecting inserts and shear pins. Under impact, there is a gradual paring away of the inserts by the knife-like edge in the adjoining tube section. The steering shaft is a two piece assembly. The upper piece is solid and has a double flattened lower end. The lower piece is hollow and formed to fit over the double flattened section of the upper piece. The purpose of the double flattened section is to provide continued steering action even though the shaft is completely collapsed. Upon impact, the shear pins break off and the shaft gradually telescopes against resistance provided by the plastic injections. The steering column mounting bracket prevents the column from being shifted towards the driver during impact. It uses two "breakaway capsules" that allow the mounting bracket to slip off its attaching points, allowing the steering column to compress or yield in a forward direction under a severe impact from the driver's end. Page 3646 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). Page 3475 Fig. 8 Speed control wiring diagram. 1986-87 Conventional Cabs & Ramchargers Page 1541 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. Specifications Page 531 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) Page 305 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) Page 3677 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). Page 3604 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 Page 1936 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. Driveline - Clunk or Snap on Acceleration or Braking Slip Yoke: Customer Interest Driveline - Clunk or Snap on Acceleration or Braking Models 1981-1984 D100, 150, 200, 250, Two-Wheel Drive Pick-Up Truck, B 100, 150, 200, 250, Ram Vans, Wagons & Voyagers Subject Driveline "Clunk" or "Snap" Index PROP SHAFT & U JOINTS Date 11/12/84 No.. 16-01-84 P-5035C This bulletin supersedes and cancels Technical Service Bulletin #16- 02-83, which should be removed from your files. This bulletin eliminates the need to replace the complete driveshaft assembly in two wheel drive trucks are described in Technical Service Bulletin #16-02-83. Four wheel drive models will be addressed in a future bulletin. SYMPTOM/CONDITION Customer concern for a "snap" or "clunk" after medium-heavy brake application to a stop is completed or when accelerating from a stop. The noise may also be heard 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 nose 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 slip yoke in the transmission extension. At the end of the stopping maneuver, the slip yoke would ordinarily slide smoothly back into the extension. The characteristic "snap" occurs when the slip yoke momentarily binds in the rearward position, then abruptly "snaps" forward to the neutral position. PARTS REQUIRED Vehicles equipped with A904/999 transmission: 1 - Yoke (nickel plated) PN 4137452 Vehicles equipped with A727 transmission: 1 - Yoke (nickel plated) PN 4137456 REPAIR PROCEDURE 1. Raise vehicle. 2. Remove driveshaft. 3. Remove slip yoke. 4. Install nickel plated slip yoke on driveshaft. 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: Page 3161 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 Page 1466 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 Testing and Inspection 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. Page 2016 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 Page 264 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 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. Page 3790 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 Page 1062 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. 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 Page 2666 Fig. 31 Four Wheel Drive Indicator Lamp Wiring Circuit. 1983-84 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. Page 2300 FIGURE 3-A Page 93 FIGURE 3-A Page 2908 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. Page 905 Fig. 37 Oil Lamp With Gauge Cluster Wiring Circuit. 1984 Page 3666 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 Page 123 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Page 3192 Suspension Spring ( Coil / Leaf ): Service and Repair 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. Page 2393 Crankshaft Position Sensor: Service and Repair 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. Page 2075 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 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 Page 94 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. Page 3911 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. Page 1943 (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. Page 1574 Manifold Pressure/Vacuum Sensor: Locations Combustion Control Computer Location. Upper RH Side Of Engine Applicable to: 1981-84 Page 3590 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. Page 2094 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. Page 2088 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). Page 90 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) Page 3009 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. Instrument Cluster - Odometer Memory Chip Service Odometer: Technical Service Bulletins Instrument Cluster - Odometer Memory Chip Service Models All Domestic Passenger Cars Equipped With Electronic Instrument Cluster Subject Instrument Cluster/ Odometer Memory Chip Service Index ELECTRICAL Date March 19, 1984 No. 08-01-84 Electronic instrument clusters contain an odometer memory chip to record the vehicle mileage. Since the chip is relatively small and delicate, certain care must be exercised in handling the device during cluster or chip service. Refer to the procedure below for proper memory chip removal and installation procedures. DIAGNOSIS Prior to servicing the instrument cluster, utilize the "Self-Diagnostic Test" procedure provided in the service manual to determine whether the cluster or the memory chip is faulty. ^ A code of 1, 2 or 3 during the first test and the word "Fail" displayed in the odometer area, indicates the cluster is defective. Replace the cluster, retaining the memory chip for installation in the replacement cluster so as to maintain the vehicle mileage. This electronic memory device contains the current accumulated vehicle mileage. Follow the procedure below to transfer the memory chip. ^ A code of "4" and the word "Fail" displayed in the odometer area indicates a probable odometer memory chip failure. Order a replacement chip package and install per the following instructions. NOTE: REPLACEMENT OF THE ODOMETER CHIP IS PERMISSIBLE ONLY WHERE ORIGINAL MILEAGE MAY BE POSTED ON A DOOR JAMB LABEL. IN AREAS WHERE LAWS REQUIRE ORIGINAL MILEAGE TO BE DISPLAYED IN ODOMETER, CONTACT HUNTSVILLE ON 1-800-328-6121. PARTS REQUIRED Odometer NVM Chip Package PN 4342218 Consists of: 1 - NVM Chip with Asterisk (*Indicates not original mileage) 1 - Instruction Sheet 1 - Speedometer Door Jamb Label REPAIR PROCEDURE 1. Remove instrument cluster per service manual procedures. 2. If service replacement chip will be used, record original mileage on speedometer door jamb label and attach to door jamb (if dashes, record last known mileage). 3. Select a clean work area. 4. Wash hands to insure that grease and dirt will not be left on the odometer chip contact pins. 5. Place the cluster front side down on a soft clean cloth. 6. Insure that the cluster is with the bottom toward the person intending to remove and install the odometer chip. Page 619 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 Page 2156 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. Page 3006 Starter Motor: Testing and Inspection Chrysler Reduction Gear Starters Diagnosis Fig. 2 Starter motor diagnosis (Part 1 of 2) Page 2899 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. Page 235 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. Page 2304 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). Page 3523 Fig. 6 Speed control wiring diagram. 1985 Conventional Cabs & Ramcharger Page 3831 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. 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. Page 2155 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). Page 3609 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 Auto Locking Hubs - Not Locking/Unlocking Wheel Hub (Locking): Customer Interest Auto Locking Hubs - Not Locking/Unlocking Models 1981-1984 "W" Model Trucks Equipped With Automatic Locking Hubs Subject Automatic Locking Hubs Will Not Operate During Low Temperatures Index FRONT SUSPENSION Date October 28, 1985 No. 02-10-85 SYMPTOM/CONDITION Customer concern of automatic locking hubs not locking/unlocking during below freezing weather. DIAGNOSIS Road test the vehicle and check for hubs locking/unlocking. NOTE: IF AMBIENT TEMPERATURES ARE ABOVE FREEZING, THE HUBS MAY OPERATE PROPERLY, THEN VISUAL INSPECTION IS REQUIRED. REMOVE THE COVER FROM THE HUB. INSPECT THE HUB FOR THE PRESENCE OF WATER CONTAMINATION. THIS WILL APPEAR IN THE FORM OF DISCOLORED GREASE OR RUST. If the hub is water contaminated, perform the following operation: PARTS REQUIRED Hub Repair Package PN 4411998 (as required) REPAIR PROCEDURE 1. Remove hub from axle. 2. Inspect the hub carefully to determine the extent of the water damage. If the hub components are corroded beyond repair, replace the hub assembly with new hub, PN 4384120. If damage to the hub is light, do the following: 3. Disassemble the hub and clean thoroughly to remove all contaminants Refer to Rear Wheel Drive Truck Service Manual for service procedure. 4. Inspect all components, especially the drag sleeve, brake band, and inner and outer cages for damage. Replace as necessary. 5. Reassemble the hub. 6. Lubricate the hub by dipping all components except the bearing and race assembly, brake band, and drag sleeve assembly in automatic transmission fluid. 7. Allow the excess transmission fluid to drip off. 8. Repack the bearing and race assembly with Darmex Lubricant, PN 4293040. 9. Lubricate the brake band and drag sleeve with Darmex Lubricant, PN 4293040. IMPORTANT: DO NOT SUBSTITUTE ANY OTHER LUBRICANT FOR THE DARMEX LUBRICANT SPECIFIED IN STEPS 8 AND 9, OR FAILURE OF THE HUB TO OPERATE PROPERLY COULD RESULT. 10. Reassemble and install the hub as outlined in the service manual. Page 1447 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). Page 608 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) Page 2215 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. Page 3502 Fig. 3 Speed control wiring diagram. 1981-84 Ramcharger, Trail Duster & Conventional Cabs Page 2873 Fig 2 Rear Wheel Cylinder 11 And 12 Inch Brakes 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: 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 Page 2111 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 Page 959 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) Page 3808 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. Page 345 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 Page 2043 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. Page 2098 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Page 3167 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. Page 3809 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 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 Page 2261 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 Page 1928 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 Page 195 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Page 1260 Crankshaft Position Sensor: Service and Repair Distributor Assembly 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. 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. Page 3025 Fuse: Service and Repair Circuit Breaker/Fuse Replacement Door Lock And Power Window Circuit Breaker And Relays Location Disconnect the battery negative terminal. Remove the two wires from the circuit breaker and remove the circuit breaker from its mounting clip. Install new circuit breaker to the mounting clip and connect the two wires. Connect the battery negative terminal and test power door lock system for proper operation. Page 1683 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). Page 1482 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. Specifications Brake Drum: Specifications Rear Inside Diameter 11.0 in Page 1919 Engine Mounted Switches & Sensors. Upper RH Side Of Engine Applicable to: V8 Engine 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. Page 2013 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. Page 3147 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 Page 3690 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* Page 1201 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 Page 591 FIGURE 3-A Locations Temperature Sensor (Gauge): Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Page 2083 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 Page 2086 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. Page 3854 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). Page 65 FIGURE 3D - BODY WIRING Page 255 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. Page 1618 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 Page 2866 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. Page 3477 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. Locations Temperature Sensor (Gauge): Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Page 2651 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. 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 Page 3656 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 Page 1308 Crankshaft Position Sensor: Service and Repair Distributor Assembly 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. Page 3002 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. Page 3827 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. Page 2730 Fig. 4 Using pry bar to remove bearing from knuckle. 44 FBJ Units w/disc brakes. Models w/full time 4WD Removal & Inspection 1. Remove axle shaft cotter pin and loosen outer axle shaft nut. 2. Raise vehicle then remove wheel assembly. 3. After removing caliper retainer and anti-rattle spring assembly, slide caliper out and away from rotor. Hang caliper out of the way. Do not allow caliper to hang by hydraulic brake hose. Remove inboard brake pad. 4. Remove outer axle shaft nut and washer. Secure a suitable puller to wheel studs and tighten main screw of tool to remove hub and rotor assembly. 5. Remove puller from hub and rotor assembly. 6. Assemble Modified Bearing Press, Tool C-293-PA, Extension, Tool C-293-3, and Adapters, Tool No. C-293-49, to hub and rotor assembly and position in a vise. Pull outer bearing cone from hub and rotor and discard outer seal. 7. Remove the six retainer bolts and retainer, then remove brake caliper adapter from knuckle, if required. 8. Place a pry bar behind inner axle shaft yoke and push bearings out of knuckle. Fig. 5 Sizing axle shaft seal surface. 44 FBJ Units w/disc brakes. Models w/full time 4WD Fig. 6 Installing bearing cups before checking bearing clamp. 44 FBJ Units w/disc brakes. Models w/full time 4WD 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. Page 2252 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. 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. Page 2336 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. Page 1989 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. Electrical Specifications Page 2272 FIGURE 3D - BODY WIRING Page 1962 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). 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 Page 2287 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. Diagram Information and Instructions Neutral Safety 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. Page 339 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Page 1903 (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. Page 2090 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 Electrical Specifications Ignition Control Module: Electrical Specifications Part No. Spark Advance Test Electronic EGR Time Delay Electronic Throttle Control 4289075 44 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289077 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289086 44 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289094 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289304 39 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289308 43 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289310 42 +/- 4 deg at 2000 rpm 20 min 20 sec 4289324 20 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289326 21 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289351 39 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289352 43 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289356 20 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289357 21 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289364 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. Page 3135 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 Page 95 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. Page 2197 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 Service Precautions Hoses: Service Precautions SERVICE PRECAUTIONS To prevent vehicle damage, always observe the following precautions: After servicing a hose, check for leaks before and after test driving the vehicle. - Always use the correct size hose. Do not use standard sized hose in place of metric hose or vice versa. Always use the correct type of hose. Never use vacuum hose in place of fuel hose. Never use heater hose in place of PCV hose. - When replacing hoses which are attached to the engine on one end and the frame or body on the other end, always leave sufficient length to compensate for engine movement (from torque). Service and Repair 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 Page 987 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. Page 3465 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. Page 1664 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 Page 495 Air/Fuel Mixture: Adjustments Idle Mixture (Propane Method) Fig. 1 Propane enrichment specification chart EXC. 1985 MODELS 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 or limiter 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. 5. Disconnect and plug vacuum hose at EGR valve, ESA computer and distributor, as required. 6. On models equipped with carburetor ground switch, connect jumper wire between switch and ground. 7. On models not equipped with Spark Control Computer (SCC), disconnect and plug vacuum hose from carburetor at heated air temperature sensor and OSAC valve, if equipped, then remove air cleaner. 8. On models with SCC, air cleaner cannot be removed but may be propped up. 9. Disconnect vacuum hose from heated air door or choke diaphragm, except as listed below, and connect hose from metering valve on enrichment tool to fitting. 10. Remove PCV valve from cylinder head cover and allow to draw underhood air. 11. Disconnect plug control hose at canister. 12. On models equipped with oxygen sensor feedback, disconnect electrical connector from oxygen sensor and ground connector. Remove and plug vacuum hose at vacuum transducer on SCC, then install suitable vacuum pump to vacuum transducer, apply 16 inches of vacuum, and allow engine to run for two minutes. 13. On models without oxygen sensor feedback, allow engine to run for one minute. 14. On all models, 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. 15. With propane flowing, adjust idle speed to specified enriched RPM, Fig. 1, by turning idle speed screw. 16. Adjust metering valve to obtain maximum RPM. If there has been a change in maximum RPM, readjust idle speed screw to specified enriched RPM. 17. Turn off main propane valve and allow engine speed to stabilize. 18. Adjust mixture screws to obtain smoothest idle at specified curb idle RPM, allowing time between adjustments for engine speed to stabilize. 19. 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 15 through 20. 20. When adjustment is correct, turn off both propane valves, stop engine and remove tool. 21. Install concealment plug, if equipped, then perform ``Curb Idle Speed, Adjust'' and ``Fast Idle Speed, Adjust'' procedure. Page 1206 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 Page 3179 Fig. 9 Installing seal slinger on outer axle shaft. 44 FBJ Units w/disc brakes. Models w/full time 4WD Fig. 10 Installing lip seal on outer axle shaft. 44 FBJ Units w/disc brakes. Models w/full time 4WD Fig. 11 Using pry bar to retain axle shaft. 44 FBJ Units w/disc brakes. Models w/full time 4WD Assembly & Installation 1. Secure steering knuckle right side up in a vise and press upper and lower ball joints into position using proper tools. Install snap ring on lower joint and new boots on both joints. 2. Thread new sleeve into ball joint yoke on axle housing ensuring that two threads are exposed at the top. 3. Position steering knuckle on axle housing yoke, then install a new lower ball joint nut and torque to 80 ft-lbs. 4. Use Tool No. C-4169 and a torque wrench to torque sleeve in upper ball joint yoke to 40 ft-lbs, then install upper ball joint nut and torque to 100 ft-lbs. Install cotter pin if slot in nuts and hole in stud align. If not, tighten, do not loosen nut to align. 5. On left side only, position steering knuckle arm over studs on steering knuckle. Install tapered dowels and nuts, then torque nuts to 90 ft-lbs. Secure drag link to steering knuckle arm and torque nut to 60 ft-lbs. 6. Secure tie rod end to steering knuckle. Torque nut to 45 ft-lbs. 7. Install brake dust shield, if removed. 8. Inspect outer axle shaft seal surface for grooving. If surface is grooved, repair as described in "Servicing Rotor Hub or Bearings". 9. Apply RTV sealer to seal surface of axle shaft then using driver, C-4398-1, install seal slinger with lip toward splines onto outer axle shaft. 10. Carefully insert axle shaft into housing so as not to damage differential seal at side gears. After sliding axle shaft completely in, wedge a pry bar through universal joint to retain shaft. Specifications Locations Thermostatic Air Cleaner Vacuum Motor: Locations Combustion Control Computer Location. Upper RH Side Of Engine Applicable to: 1981-84 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. Page 2203 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 Front Suspension Spring ( Coil / Leaf ): Service and Repair Front 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. Page 895 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. Page 2738 Fig 5 Removing Or Installing Caliper Assembly & Installation 1. Install inner and outer bearing cups in rotor. 2. Lubricate and install inner bearings, then install the grease seal using suitable tools. 3. Install rotor, then the outer wheel bearing. 4. Install inner locknut and torque to 50 ft-lbs, using tool C-4170, to seat bearings. 5. Loosen inner locknut, then retorque to 30-40 ft-lbs, while rotating hub. Back off locknut 135° to 150°. Set retaining washer in position by turning nut so that the pin pressed into locknut will engage nearest hole in washer. 6. Install outer locknut and torque to 50 ft-lbs. End play after final bearing adjustment should be 0.001-0.010 inch. 7. Install retaining spring plate, retaining spring with large end first, driving hub, snap ring and grease cap. 8. On all models, install inboard brake shoe on adapter with shoe flanges in adapter slots, then install caliper assembly. Use care not to pull dust boot out of its grooves while sliding piston and boot over the inboard shoe. 9. Install anti-rattle springs and retaining clips and torque to 180 inch lbs. The inboard shoe anti-rattle spring must be installed on top of the retainer spring plate. 10. Install wheel assembly, then lower truck and test operation. Page 1191 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. Page 124 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Page 4047 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. Page 589 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). With Tilt Steering Column: Service and Repair With Tilt Removal/Installation Fig. 1 Steering column installation. Motor Home MOTOR HOME Removal 1. Disconnect battery ground cable. 2. Remove pot coupling to steering gear shaft clamp nut and bolt. 3. Disconnect electrical connector at column jacket. 4. Remove horn and pad assembly, then remove steering wheel using a suitable puller. Do not attempt to remove steering wheel using a hammer as damage to the steering column and shaft will result. 5. Remove the 4 boot floor plate retaining bolts. 6. Remove the two column clamp to tilt assembly screws and remove column. Installation 1. Place floor plate and boot on column, then slide column assembly through floor pan opening. 2. Position column so that steering shaft bearing blocks are centered in the pot coupling, then torque the clamp bolt to 35 ft lb 3. Install but do not tighten steering column upper bracket bolts. 4. With wheels in a straight ahead position, center the steering shaft in the column. 5. Center boot and floor plate and tighten screws. 6. Torque the steering column bracket bolts to 30 ft lb 7. Install steering wheel with master splines aligned and torque nut to 27 ft lb Do not drive wheel onto shaft, use nut to draw it down. 8. Install horn switch parts, connect battery ground cable and check operation of lights and horn. Page 1894 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. Engine - High Altitude Conversion Package Air/Fuel Mixture: Technical Service Bulletins Engine - High Altitude Conversion Package Models 1984 318-4V & 360-4V Heavy Duty Truck Subject High Altitude Conversion Package & Adjustment for Improved Engine Performance Index EMISSIONS Date 11/12/84 No. 25-05-84 P-5036C A package is now available to accommodate a customer who wishes to convert his 1984 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 1984 non-altitude equipped engine families in service at altitudes above 4,000 feet above sea level.. CONVERSION INSTRUCTIONS Sea Level to Altitude IMPORTANT: IN SOME OF THE CONVERSION PROCEDURES YOU WILL BE REQUIRED TO INSTALL A NEW VEHICLE EMISSION CONTROL INFORMATION UPDATE (VECIU) LABEL, PN 4275084. FIGURE 1 THIS LABEL HAS TWO AREAS THAT ARE IMPACT IMPRINTABLE WITH A TYPEWRITER (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, THEN JUST TYPE IN THE NEW SPECIFICATION AFTER THE SUBJECT OPERATION. IF YOU ARE ASKED TO REFER TO THE ORIGINAL VECI Page 2263 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 Page 3667 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. Page 3544 Fig. 4 Speed control wiring diagram. 1982-84 Rampage & 1983 Scamp Page 1567 Information Bus: Diagnostic Trouble Code Tests and Associated Procedures For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes Locations Clutch Switch: Locations On Clutch Pedal Page 1369 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 Page 3868 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* Page 2924 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. 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. Page 3687 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 Page 3405 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 Page 1049 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Page 2752 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. Page 781 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. 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: Page 3595 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. Page 2196 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 Locations Oxygen Sensor: Locations Engine Mounted Switches & Sensors. Lower RH Side Of Engine Applicable to: V8 Engine Page 3170 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. Page 3485 Fig. 4 Speed control wiring diagram. 1982-84 Rampage & 1983 Scamp Page 594 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 Electrical Specifications Ignition Control Module: Electrical Specifications Part No. Spark Advance Test Electronic EGR Time Delay Electronic Throttle Control 4289075 44 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289077 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289086 44 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289094 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289304 39 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289308 43 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289310 42 +/- 4 deg at 2000 rpm 20 min 20 sec 4289324 20 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289326 21 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289351 39 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289352 43 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289356 20 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289357 21 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289364 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. Page 2746 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. Page 209 Fig. 8 Speed control wiring diagram. 1986-87 Conventional Cabs & Ramchargers Page 3858 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 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. Page 2615 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 Page 2902 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 Page 492 LABEL SPECIFICATIONS, TYPE IN ON THE RIGHT HAND SIDE OF THE LABEL "REFER TO ORIGINAL VECI LABEL". IN EVERY CASE WHERE THIS LABEL IS USED, TYPE IN AFTER - AUTHORITY OF TECHNICAL SERVICE BULLETIN #25-05-84, AND YOUR DEALER CODE BELOW. LABEL PN 4275084 IS AVAILABLE FROM PARTS SUPPLY. Conversion Procedure 1. On the 360-4V only, replace the secondary metering jets with PN 4293720. 2. Relieve the tension on the secondary air valve spring by one turn clockwise (both 318 and 360). 3. Adjust the secondary air valve opening to 1/2" (both 318 and 360). 4. Reset basic timing from 4~ to 8~ BTD on 360-4V and from 8~ to 12~ BTD on 318-4V. 5. Reset idle and propane speeds to sea level specifications at altitude. 6. Refer to 1984 Rear Wheel Drive Truck Service Manual for correct procedures for the above adjustments. 7. Type Vehicle Emission Control Information Update Label, PN 4275084, as shown in Figure 1 and install next to or near the original VECI label. NOTE: VEHICLE SHOULD BE RETURNED TO ITS ORIGINAL CONDITION IF DRIVEN AT LOW ALTITUDE. POLICY: Information only 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. Page 250 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. Page 3549 Fig. 9 Speed control wiring diagram. 1986 rear wheel drive Ram Van & Wagons Page 206 Fig. 5 Speed control wiring diagram. 1984 Mini-Vans/Wagons (1985 similar) Page 2132 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). Page 118 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. Page 293 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 Page 2087 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). Page 1701 Engine Control Module: Locations Engine Control Module Combustion Control Computer Location. Upper RH Side Of Engine Applicable to: 1981-84 Page 3275 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. Page 1122 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. Page 1990 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. Service and Repair 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. 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). 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 Page 3626 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 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. Page 3901 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. Engine - High Altitude Conversion Package Air/Fuel Mixture: Technical Service Bulletins Engine - High Altitude Conversion Package Models 1984 318-4V & 360-4V Heavy Duty Truck Subject High Altitude Conversion Package & Adjustment for Improved Engine Performance Index EMISSIONS Date 11/12/84 No. 25-05-84 P-5036C A package is now available to accommodate a customer who wishes to convert his 1984 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 1984 non-altitude equipped engine families in service at altitudes above 4,000 feet above sea level.. CONVERSION INSTRUCTIONS Sea Level to Altitude IMPORTANT: IN SOME OF THE CONVERSION PROCEDURES YOU WILL BE REQUIRED TO INSTALL A NEW VEHICLE EMISSION CONTROL INFORMATION UPDATE (VECIU) LABEL, PN 4275084. FIGURE 1 THIS LABEL HAS TWO AREAS THAT ARE IMPACT IMPRINTABLE WITH A TYPEWRITER (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, THEN JUST TYPE IN THE NEW SPECIFICATION AFTER THE SUBJECT OPERATION. IF YOU ARE ASKED TO REFER TO THE ORIGINAL VECI 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 Page 1426 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine 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) Page 2324 FIGURE 3C - BODY WIRING Page 1204 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 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. Page 3125 Fig. 9 Non-tilt wheel steering column exploded view (column shift auto. trans.) Vans & Wagons exc. front wheel drive Fig. 10 Non-tilt wheel steering column exploded view (floor shift man. trans.) Vans & Wagons exc. front wheel drive Page 1676 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. Page 1197 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). Engine - Valve Train Noise Rocker Arm Assembly: All Technical Service Bulletins Engine - Valve Train Noise Models 1984 Rear Wheel Drive Passenger Car Equipped W/318 Engine; 1984 Rear Wheel Drive Truck & Vans Equipped W/318 or 360 Engine Subject Valve Rocker Arm Breakage Index ENGINE Date December 21, 1984 No.. 09-11-84 SYMPTOM/CONDITION Noise in valve train. DIAGNOSIS Remove valve cover and inspect rocker arms for breakage in the push rod area. The push rod may have penetrated the rocker arm. PARTS REQUIRED Passenger Car & Truck 8 - Rocker Arm PN 4100774 8 - Rocker Arm PN 4100775 REPAIR PROCEDURE When a rocker arm is found to have failed in the above manner in the subject model engines, it is necessary to replace all 16 rocker arms and inspect the push rods. 1. Remove valve covers. 2. Remove all rocker arms and replace with new ones. 3. Inspect push rods and replace as necessary. 4. Reinstall rocker shafts and torque screws to 25 foot pounds (34 N-m). 5. Replace valve cover gaskets and reinstall valve covers. Tighten valve cover screws to 80 inch pounds (9 N-m). POLICY: Information only Page 347 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 Page 3682 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. Page 979 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) 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: Page 3665 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 Page 3888 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. Page 3071 Multiple Junction Connector: Electrical Diagrams Fig. 27 Engine Compartment ECU Ignition Wiring Circuit (Part 1 of 3). 1983-84 W/V8 Engine Page 2424 Pick-Up Coil: Service and Repair 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. Page 2290 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 Page 1307 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. Locations Choke Temperature Control Switch: Locations Upper RH Side Of Engine Page 629 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. Page 2723 Brake Disc: Testing and Inspection Fig 2 Disc Measuring Points 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 Rear Axle Shaft Oil Seal - Update Seals and Gaskets: Technical Service Bulletins Rear Axle Shaft Oil Seal - Update Models All 1984 Rear Wheel Drive Domestic Vehicles Equipped With 7-1/4, 8-1/4, 9-1/4 (Std.) Axle Subject New Rear Axle Shaft Oil Seal Index REAR AXLE Date November 19, 1984 No. 03-03-84 P-5121-C A new Axle Shaft Oil Seal, PN 4137426, was incorporated into all 7-1/4, 8-1/4, and 9-1/4 (standard) axles during April, 1984. The new seal replaces the old seal, PN 2931875, in all of these applications, and will service prior model year applications. The new seal features a flange which insures installation to the proper depth, and incorporates a sealant on the outside diameter. These features provide improved sealing. The new seal can be installed by using existing Miller Special Tool. Use Miller Special Tool #C-4202 and handle #C-4171 to install the seal. Turn Tool #C-4202 so that the flat side is against the seal. Drive the seal flange flush with the axle housing. CAUTION: DO NOT USE SPECIAL SERVICE TOOL #C-4130 CALLED OUT IN THE SERVICE MANUALS, AS THE FLANGE WILL BE DAMAGED AND AN OIL LEAK MAY RESULT. THE CURRENT SEAL, PN 2931875. WILL CONTINUE TO BE USED FOR SERVICE UNTIL THE NEW SEAL, PN 4137426, IS AVAILABLE FOR SERVICE. POLICY: Information only Page 1679 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. 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: Page 3799 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. Page 1143 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). Page 83 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 Page 3047 Fig. 28 Engine Compartment Electrical Spark Advance (Less Feedback Carburetor, Part 3 of 3) Wiring Circuit. 1983-84 Specifications Hydraulic Lash Adjuster: Specifications Lifter Bore Diameter .9051-.9059 in Lifter Diameter .9035-.9040 in Lifter To Bore Clearance .0011-.0024 in Page 3692 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 Page 2533 SMALLER "C" LOCK AND COMPONENT PARTS EXCEPT AS ASSEMBLIES. Service procedures remain the same as 1984 9-1/4 axles. Small "C" Lock Large "C" Lock Axle Shaft 4.50" B.C. PN 3723824 PN 4137428 Axle Shaft 5.50" B.C. PN 4037726 PN 4137429 Differential Side Gear PN 4137319 PN 4137675 "C" Lock PN 2852883 PN 4137669 Sure Grip Partial PN 3723691 PN 4137425 Assembly POLICY: Information only 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. Page 3030 Fig. 1 Fuse Panel. 1983-84 Page 2640 Fig. 31 Four Wheel Drive Indicator Lamp Wiring Circuit. 1983-84 Page 2734 Fig. 11 Using pry bar to retain axle shaft. 44 FBJ Units w/disc brakes. Models w/full time 4WD Assembly & Installation 1. Apply RTV sealer or equivalent to seal surface of axle shaft. 2. Using driver, Tool No. C-4398-1, install seal slinger with lip toward splines onto outer axle shaft. 3. Carefully insert axle shaft into housing so as not to damage differential seal at side gears. After sliding axle shaft completely in, wedge a pry bar through universal joint to retain shaft. Fig. 12 Using driving & adapter to install seal cup into knuckle. 44 FBJ Units w/disc brakes. Models w/full time 4WD Fig. 13 Tools in place after seal cup is installed. 44 FBJ Units w/disc brakes. Models w/full time 4WD Transaxle/Transmission - Automatic Fluid - A/T: Specifications Transaxle/Transmission - Automatic TYPE.................................................................................................................................................... ........................................................................AF, AP CAPACITY, Initial Refill*: All models w/o torque converter drain..............................................................................................................................................3.8 Liters 4.0 Quarts *With the engine at operating temperature, shift transmission through all gears. Check fluid level in PARK and add fluid as needed Page 1503 FIGURE 3-A Page 3489 Fig. 8 Speed control wiring diagram. 1986-87 Conventional Cabs & Ramchargers Page 3072 Fig. 27 Engine Compartment ECU Ignition Wiring Circuit. 1983-84 W/V8 Engine Page 1787 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. Page 1364 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). Page 3534 Fig. 5 Speed control wiring diagram. 1984 Mini-Vans/Wagons (1985 similar) Wheel Cover - Loose/Falls Off Wheels: Customer Interest Wheel Cover - Loose/Falls Off Models 1984 D, W & B 250 - 350 Dodge Pick-Up Trucks & Van/Wagons Subject Wheel Cover Retention With 16.5 x 6.75 H.D. Wheels Index WHEELS & TIRES Date November 12, 1984 No. 22-01-84 P-4993-C SYMPTOM/CONDITION A small number of subject vehicles may exhibit a condition of lack of wheel cover/hub cap retension on one or more of the wheels. The wheel covers/hub caps may not grip the embossment on the wheel, thus the cover will not stay on. This occurs primarily during installation at new vehicle pre-delivery. If the above condition occurs, the wheel must be replaced. PARTS REQUIRED 16.5 x 6.75 H.D. Wheel PN 4284446 NOTE: REPLACED WHEELS MUST BE RETURNED TO THE MATERIAL RETURN CENTER. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 22-40-01-02 . . . . . . . . . . . 0.6 Hrs. FAILURE CODE: HR - Improper Retention Page 1902 (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. Page 1982 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). Page 3593 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. Page 110 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 Page 2733 Fig 5 Removing Or Installing Caliper Removal & Inspection 1. Remove locking hub assembly, if equipped. 2. Raise and support vehicle, then remove wheel assembly. 3. Remove caliper retainer and anti-rattle assemblies. 4. Remove caliper from disc and support caliper to prevent damage to brake line. 5. Remove inboard brake shoe. 6. Remove grease cap and driving hub snap ring, then the driving hub and retaining spring. 7. On all models, remove wheel bearing adjusting locknut using tool C-4170 or equivalent, then the washer and adjusting nut. 8. Remove rotor assembly. The outer wheel bearing and retainer spring plate will slide out as rotor is removed. 9. Pry inner wheel bearing grease seal from hub, then remove bearing cone and the inner and outer bearing cups. With Full Time 4WD Fig. 9 Installing seal slinger on outer axle shaft. 44 FBJ Units w/disc brakes. Models w/full time 4WD Fig. 10 Installing lip seal on outer axle shaft. 44 FBJ Units w/disc brakes. Models w/full time 4WD Page 3613 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. Electrical Specifications Page 1634 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. Page 2650 FIGURE 4 - Control Shaft 4. Control Shaft The shifter handle was changed in shape as shown in Figure 4. FIGURE 5 - Control Lever 5. Control Lever The lever has been changed in shape to comply with the change in shift pattern. Furthermore, the lever hole in the stopper plate has been changed in shape (Figure 5). POLICY: Information only Page 1988 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). 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. Page 3670 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. Page 2271 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. 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. 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. 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. Page 598 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. Page 2548 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. Page 3581 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. Wheel Cover - Loose/Falls Off Wheel Cover: Customer Interest Wheel Cover - Loose/Falls Off Models 1984 D, W & B 250 - 350 Dodge Pick-Up Trucks & Van/Wagons Subject Wheel Cover Retention With 16.5 x 6.75 H.D. Wheels Index WHEELS & TIRES Date November 12, 1984 No. 22-01-84 P-4993-C SYMPTOM/CONDITION A small number of subject vehicles may exhibit a condition of lack of wheel cover/hub cap retension on one or more of the wheels. The wheel covers/hub caps may not grip the embossment on the wheel, thus the cover will not stay on. This occurs primarily during installation at new vehicle pre-delivery. If the above condition occurs, the wheel must be replaced. PARTS REQUIRED 16.5 x 6.75 H.D. Wheel PN 4284446 NOTE: REPLACED WHEELS MUST BE RETURNED TO THE MATERIAL RETURN CENTER. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 22-40-01-02 . . . . . . . . . . . 0.6 Hrs. FAILURE CODE: HR - Improper Retention 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. Page 2395 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. 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. Removal & Installation Crankshaft Position Sensor: Service and Repair 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. Page 616 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. Page 2703 Fig 14 Installing Piston Seal 1. Clamp caliper in vise (with protector jaws). CAUTION: Excessive vise pressure will cause bore distortion and binding of piston. 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. Page 2814 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. 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. Page 2718 Fig 1 Disc Brake Assembly (Rear View) 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. 9. Remove jack stands or lower hoist. 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: Page 297 *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 Page 2029 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. 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. Page 61 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. Page 3774 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. Page 2209 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). Page 1721 Crankshaft Position Sensor: Service and Repair 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. Page 1472 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 Page 1625 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. Diagram Information and Instructions Trailer Connector: 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. Page 3816 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 Page 3835 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 Page 3459 Fig. 4 Speed control wiring diagram. 1982-84 Rampage & 1983 Scamp Page 1456 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. Page 2284 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. Page 1155 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. 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. Page 3347 Trailer Connector: Electrical Diagrams Fig. 45 Trailer Tow & Camper Wiring Circuit (Part 1 of 2). 1983-84 Fig. 45 Trailer Tow & Camper Wiring Circuit (Part 2 of 2). 1983-84 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. Page 2804 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. Page 3650 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. Testing and Inspection 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. Page 1619 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. Page 2289 *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 Page 3611 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 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. Locations EGR Control Valve: Locations Exhaust Gas Recirculation (EGR) System Components In Air Cleaner Housing Page 2623 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 Page 2195 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. Page 1120 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. Page 3798 FIGURE 3D - BODY WIRING 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. Page 1616 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 Page 1210 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. Page 80 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. Page 309 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. Page 991 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 Page 1202 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. 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. Page 329 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). Page 1387 TIMING MARK 1981-90 Some 5.2L & 5.9L Page 326 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 Page 3976 Trailer Lighting Module: Electrical Diagrams Fig. 45 Trailer Tow & Camper Wiring Circuit (Part 1 of 2). 1983-84 Fig. 45 Trailer Tow & Camper Wiring Circuit (Part 2 of 2). 1983-84 Page 3120 Assembly Fig. 27 Shift tube installation. Except front wheel drive Mini-Vans/Wagons During assembly, lubricate all friction surfaces with NLGI grade 2 E.P. or equivalent grease. 1. Install bearing in housing, if removed. 2. Install lock shoe springs, lock shoes and shoe in bearing housing. Use a 0.180 inch rod to align shoes for pin installation. With tilt lever opening on left side and shoes facing up, the four slot shoe is on the left. 3. Install spring, release lever and pin in bearing housing. Relieve load on release lever as described in step 30 in the "Disassembly" procedure. 4. Install drive shaft in housing, then lightly tap sector onto shaft just enough to allow snap ring installation. 5. Install lock bolt and engage with sector cam surface. 6. Install rack and spring. Block tooth on rack to engage block tooth on sector, then install external tilt release lever. 7. Install bolt spring and spring retaining screw and torque to 35 inch lbs. 8. Install shift lever spring in bowl by winding up with pliers and pushing in. Slide bowl into jacket. 9. Install wave washer and lock plate into position, then work lock plate into notches in jacket by tipping lock plate toward bowl at 12 o'clock position and under jacket opening. Slide lock plate into notches in jacket. 10. Carefully install shift tube in lower end of jacket. Align key in tube with keyway in bowl and use tool C-4119 or equivalent to pull shift tube into bowl. Install thrust washer and retaining ring by pulling bowl up to compress wave washer. Do not push or tap end of shift tube. 11. Install support by aligning "V" in support with "V" notch in jacket. Install screws through support into lock plate and torque to 60 inch lbs. 12. If removed, install lower bearing in lower end of shift tube. Locate it about 3/16 inch inside of tube and use lubricant to ease installation. 13. Install centering spheres and anti-lash spring in upper steering shaft, then install lower steering shaft from same side of spheres that spring ends protrude. Check fit of double coupling assembly to assure that master serration of upper shaft aligns with master serration of pot coupling. 14. Place housing in full up position and install guide, tilt spring, and tilt spring retainer using a screwdriver in retainer slot. Turn retainer clockwise to engage. 15. Install steering shaft assembly in shift tube upper end. 16. Install ignition switch and actuator rod through bowl from bottom and insert support slot. Extend rack downward from bearing housing, then assemble bearing housing over steering shaft and engage rack over end of actuator rod. 17. Install external tilt release lever, then while holding lock shoes in disengaged position, assemble bearing housing over steering shaft until pivot pin holes align and install pivot pins. 18. Place housing in full up position, then install guide plate after making sure there is grease between the guide and peg on support, tilt spring and tilt spring retainer. Using a screwdriver, turn retainer clockwise to engage. 19. Install bearing inner race and seat, then install tilt release lever shield. 20. Remove tilt release lever, then install housing cover and torque retaining screws to 100 inch lbs. 21. If used, assemble buzzer switch to spring clips with formed end of clips under end of switch and spring bowed away from switch on side opposite contact. Push spring into hole in cover to the step with contacts toward the lock cylinder bore. Install combination switch onto steering column. Connect electrical connectors onto combination switch. 22. Insert turn signal switch wires and connector through cover, bearing housing and bowl. Push hazard warning plunger in, install switch and tighten screws to 25 inch lbs. 23. Install hazard warning knob and pull out, then install cancelling spring, cancelling cam and shift lock plate. 24. Using tool C-4156 or equivalent, depress shift lock plate and install a new snap ring. 25. Install tilt release lever and turn signal switch lever. 26. On models with a key warning buzzer, turn ignition lock to Lock position and remove key. This will cause buzzer operating lever to retract in cylinder. Insert cylinder into housing far enough to contact switch actuator. Press in and move switch actuator rod up and down to align parts. When parts align, the cylinder will move inward allowing a spring loaded retainer to snap into place, locking the cylinder to the housing. 27. On vehicles without a key warning buzzer, turn ignition lock to Lock position and remove key. Insert cylinder into housing far enough to contact switch actuator. Press inward and move switch actuator rod up and down to align parts. When parts align, the cylinder will move inward allowing spring loaded retainer to snap into place, locking the cylinder to the housing. 28. To install ignition switch, position key cylinder in Accessory detent (full counterclockwise and then to the extreme other end). 29. Slide rod into slider hole and assemble loosely to column with two screws. Lightly push the switch down the column to remove lash from actuator rod and torque retaining screws to 35 inch lbs. 30. Install wire protector over wires on column using care to avoid pinching wires. 31. Remove column holding fixture, then install bracket to column and torque bolts to 120 inch lbs. 32. Align master splines and install coupling assembly and roll pin on steering shaft. 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. Testing and Inspection 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 Service and Repair 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 Page 3471 Fig. 4 Speed control wiring diagram. 1982-84 Rampage & 1983 Scamp 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. Page 961 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. Diagram Information and Instructions Intake Air Temperature 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. Page 990 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 Page 1510 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. Page 1347 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. Page 2305 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. Page 342 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. Page 601 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 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 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: Page 2898 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. 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. Specifications 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 Page 1425 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Page 1938 (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. 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. Page 1508 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. Page 3655 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. Page 3084 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. Page 1312 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. Page 1457 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 Page 2166 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 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. Page 1546 *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 Page 762 Camshaft: Specifications Valve Timing 18 deg BTDC Page 2050 *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 Page 222 Fig. 9 Speed control wiring diagram. 1986 rear wheel drive Ram Van & Wagons Page 1259 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. Page 2930 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. Page 677 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. Page 3669 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). Radio - No AM/Weak FM Reception Antenna: Technical Service Bulletins Radio - No AM/Weak FM Reception Models All 1984 Vehicles Equipped With Standard AM-FM Mux Radio (Sales Code RAL) Subject No AM and Weak FM Radio Reception Index ELECTRICAL Date February 14, 1984 No. 08-08-84 P-536 SYMPTOM/CONDITION Radio reception coming in weak on FM stations and not at all on AM stations may be due to the antenna plug short circuiting inside the radio. This condition is similar to a failed antenna. DIAGNOSIS To determine whether the radio or antenna is at fault: 1. To gain access to the back of the radio, slide the radio out of the instrument panel without disconnecting any wires. 2. Turn radio on and tune to a local AM station. Page 2131 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) Auto Locking Hubs - Not Locking/Unlocking Wheel Hub (Locking): All Technical Service Bulletins Auto Locking Hubs - Not Locking/Unlocking Models 1981-1984 "W" Model Trucks Equipped With Automatic Locking Hubs Subject Automatic Locking Hubs Will Not Operate During Low Temperatures Index FRONT SUSPENSION Date October 28, 1985 No. 02-10-85 SYMPTOM/CONDITION Customer concern of automatic locking hubs not locking/unlocking during below freezing weather. DIAGNOSIS Road test the vehicle and check for hubs locking/unlocking. NOTE: IF AMBIENT TEMPERATURES ARE ABOVE FREEZING, THE HUBS MAY OPERATE PROPERLY, THEN VISUAL INSPECTION IS REQUIRED. REMOVE THE COVER FROM THE HUB. INSPECT THE HUB FOR THE PRESENCE OF WATER CONTAMINATION. THIS WILL APPEAR IN THE FORM OF DISCOLORED GREASE OR RUST. If the hub is water contaminated, perform the following operation: PARTS REQUIRED Hub Repair Package PN 4411998 (as required) REPAIR PROCEDURE 1. Remove hub from axle. 2. Inspect the hub carefully to determine the extent of the water damage. If the hub components are corroded beyond repair, replace the hub assembly with new hub, PN 4384120. If damage to the hub is light, do the following: 3. Disassemble the hub and clean thoroughly to remove all contaminants Refer to Rear Wheel Drive Truck Service Manual for service procedure. 4. Inspect all components, especially the drag sleeve, brake band, and inner and outer cages for damage. Replace as necessary. 5. Reassemble the hub. 6. Lubricate the hub by dipping all components except the bearing and race assembly, brake band, and drag sleeve assembly in automatic transmission fluid. 7. Allow the excess transmission fluid to drip off. 8. Repack the bearing and race assembly with Darmex Lubricant, PN 4293040. 9. Lubricate the brake band and drag sleeve with Darmex Lubricant, PN 4293040. IMPORTANT: DO NOT SUBSTITUTE ANY OTHER LUBRICANT FOR THE DARMEX LUBRICANT SPECIFIED IN STEPS 8 AND 9, OR FAILURE OF THE HUB TO OPERATE PROPERLY COULD RESULT. 10. Reassemble and install the hub as outlined in the service manual. 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. Page 122 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). Diagrams Timing Marks and Indicators: Diagrams TIMING MARK 1981-85 5.2L & 5.9L Page 361 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. Page 3469 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 Page 3127 Steering Shaft 1. Remove snap ring from upper end of steering shaft. 2. Remove 3 screws retaining bearing housing to lock housing. These screws must be removed before steering shaft is removed. 3. Remove bearing housing from shaft, and then the coil spring. 4. Remove lock plate from shaft, then remove shaft through lower end of column. Lock Housing 1. If equipped with shift indicator dial, remove pointer screw and position pointer aside. 2. If equipped, remove screw and lift out buzzer switch. 3. Remove 2 retaining screws and lock lever guide plate to expose the lock cylinder release hole. 4. Place cylinder in "Lock" position and remove key. Insert a small screwdriver into lock cylinder release hole and push in to release spring loaded lock retainer, while pulling lock cylinder out of the housing. 5. Remove the 3 retaining screws and ignition switch assembly. 6. Grasp lock lever and spring assembly and pull straight out of housing. 7. Remove the four lock housing to column jacket hex retaining screws and remove housing from jacket. Shift Tube 1. On Ramcharger, Trailduster and D/W-100 thru 400 series models with automatic transmission, loosen shift tube set screw in shift housing and remove shift tube through lower end of jacket. 2. On Van and Wagon models with automatic transmission, remove indicator bracket and then the shift tube through the lower end of the jacket. 3. On Van and Wagon models with manual transmission, remove the three bearing support screws at lower end of jacket and the three adjustable bushing screws from cam slots in jacket, then remove shift tube and lever assembly through lower end of jacket. 4. On all models, remove floor plate and grommet from jacket. Fig. 13 Steering shaft flex coupling exploded view Steering Shaft Flex Coupling 1. Remove the 4 bolts and two cross straps. 2. Remove flex coupling. 3. Check coupling and cross straps for cracks, warpage or distortion. Replace as required. 4. Position flex coupling in the two cross straps, then install two long and short attaching bolts. Ensure that master spline on steering shaft lines up with master spline in lower pot coupling during assembly. 5. Torque coupling attaching bolts to 200 inch lbs. Fig. 14 Steering shaft pot coupling exploded view Steering Shaft "Pot" Coupling 1. Pry cover tangs from coupling body and lift seal and cover from body. 2. Drive the small short dowel pin at edge of body coupling, down into coupling. A new dowel pin will be required during assembly. Page 2097 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Page 2939 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 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. Page 3843 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 Page 2135 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. Page 2743 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. Page 4040 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. Page 3875 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. Page 1535 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 Page 2068 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. Page 3473 Fig. 6 Speed control wiring diagram. 1985 Conventional Cabs & Ramcharger 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. Page 3780 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 Page 748 11. Install new cover and screws with "O" rings, PN 4411998. 12. Torque the cover screws to 40-50 inch pounds (4.5 - 5.6 N-m). 13. Check the hubs for locking/unlocking. POLICY: Information only Page 2003 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. Page 270 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 Locations Temperature Sensor (Gauge): Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Page 1972 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 Page 62 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 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: Page 2139 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. Page 1766 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. Voltmeter - Explanation for High Readings Volt Meter Gauge: Technical Service Bulletins Voltmeter - Explanation for High Readings Models All 1984 Models Equipped With Magnetic Voltmeter Instrument Clusters Subject High Voltmeter Readings Index ELECTRICAL Date March 19, 1984-C No. 08-11-84 P-982-C SYMPTOM/CONDITION The magnetic type of voltmeters used in subject 1984 vehicles are sensitive to heat build up inside the instrument cluster housing. The increased heat that builds up places the voltmeter indicator toward the high end of the "normal" operating portion of the meter or, under the right conditions, may just enter the "high warning" portion of the meter. The conditions causing this high reading are as follows: ^ An hour or more of continuous driving at cold ambient temperatures (cold temperature operation causes the voltage regulator output to be higher than hot temperature operation). ^ Instrument cluster illumination lamps and/or heater/defroster on, which increases temperatures around the voltmeter. If a high voltmeter reading exists, verify battery and charging system are operating normally per service manual procedures. If system meets specifications, assure customer that system is operating properly. Do not replace voltage regulator or voltmeter if test results meet service manual specifications. A defective voltage regulator (overcharging) will normally cause the voltmeter to read well into the warning area (full scale) and will occur immediately, not over a period of an hour or more. POLICY: Information only Page 1476 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. Page 3624 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Page 1467 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 Page 3627 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. Page 3269 Blower Motor: Locations Without A/C Heater Without A/C RH Side Of Engine Compartment Applicable to: Models Less A/C Page 3734 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. 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. Page 2136 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. Page 472 Power Window Switch: Service and Repair Door Components Page 2892 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. Page 1639 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 Page 1783 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. Page 1057 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. Page 3322 Radio/Stereo: Electrical Diagrams Fig. 39 Radio Wiring Circuit 1984 (AM With Front Speaker). Fig. 41 Radio Wiring Circuit 1984 (AM-FM Electronically Tuned). Specifications 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) 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. Page 1156 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. Page 2970 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: Page 958 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. Page 3728 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. Page 74 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 Page 317 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 Page 3797 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. Page 2006 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. Page 2242 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. Page 3597 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 Page 3603 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 Page 2047 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. Page 280 FIGURE 3D - BODY WIRING Page 969 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. 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. Page 3487 Fig. 6 Speed control wiring diagram. 1985 Conventional Cabs & Ramcharger Page 2616 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 Page 1344 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). Page 2339 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 Page 3492 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. Diagram Information and Instructions Engine 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. Page 928 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. Page 135 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* Page 2809 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 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. 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. Page 555 TIMING MARK 1981-90 Some 5.2L & 5.9L Page 2825 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. Page 2731 Fig. 7 Installing bearing retainer to check bearing clamp. 44 FBJ Units w/disc brakes. Models w/full time 4WD Fig. 8 Checking bearing clamp. 44 FBJ Units w/disc brakes. Models w/full time 4WD 9. Remove and discard O-ring from knuckle, if equipped, then carefully remove axle shaft assembly. Examine inner seal surface and knuckle bore for wear or damage and replace knuckle if required. If outer axle shaft seal surface is grooved, repair as follows: a. Measure in from yoke shoulder of axle approximately 3/8 inch. Use a center punch and stake at 1/4 inch intervals around circumference of shaft. This will size shaft and ensure a tight fit of inner seal slinger. b. Proper bearing clamp should be checked by installing bearing cups and spacer into knuckle bore and bolting bearing retainer to knuckle. If a 0.004 inch feeler gauge can not be inserted between knuckle and retainer at the six places midway between retainer mounting ears, the knuckle must be replaced. The brake dust shield may have to be removed to complete this check. If knuckle is serviceable, remove retainer, bearing cups and spacer and install dust shield if removed. With Part Time 4WD Page 2739 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. CAUTION: Do not reface a disc brake rotor more than 0.030 inch (0.762mm) less than the original disc minimum thickness. Reface both sides of rotor, not exceeding 0.030 (0.762mm) total. NOTE: 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 in (23.8mm) - Allow for Wear 0.030 in (0.762mm) - Do Not Reface Beyond 0.970 in (24.6mm) Page 3021 Circuit Breaker: Service and Repair Door Lock And Power Window Circuit Breaker And Relays Location Disconnect the battery negative terminal. Remove the two wires from the circuit breaker and remove the circuit breaker from its mounting clip. Install new circuit breaker to the mounting clip and connect the two wires. Connect the battery negative terminal and test power door lock system for proper operation. Page 1964 FIGURE 3-A Page 3733 Fig. 37 Oil Lamp With Gauge Cluster Wiring Circuit. 1984 Page 2929 Fig. 8 Automatic Trans Neutral Star Switch Wiring Circuit. 1983-84 Page 1249 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Page 313 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. Page 2624 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. Page 2430 Ignition Control Module: Mechanical Specifications Part No. Spark Advance Test Electronic EGR Time Delay Electronic Throttle Control 4289075 44 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289077 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289086 44 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289094 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289304 39 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289308 43 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289310 42 +/- 4 deg at 2000 rpm 20 min 20 sec 4289324 20 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289326 21 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289351 39 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289352 43 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289356 20 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289357 21 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289364 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. Page 2745 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. Page 1027 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". Page 3418 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 BODY CODEPLATE The Body Code Plate is located on the Left Front Side Shield or Wheel Housing or on the Upper Radiator Support. The Plate contains 7 rows of data. The bottom 3 rows are reserved for specific information as depicted below. Starting at the fourth row, (following the reserved portion), other Sales Codes used to build a specific vehicle are listed in the ascending order by Alpha sequence. Specifications Fluid - Transfer Case: Specifications NP205................................................................................................................................................... .............................................................GL-5, SF, SG SF, SG: Above 32°F 50; below 32°F (0°C), 30 GL-5: Above 90°F (32°C), 140; above -10°F (-23°C), 90; 90; below -10°F (-23°C), 80W NP208........ .............................................................................................................................................................. .....................................................AF, AP CAPACITY, Refill: NP205................................................... .................................................................................................................................................2.1 Liters 4.5 Pints NP208................................................................................................................................................... .................................................2.8 Liters 6.0 Pints 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. Page 40 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. Page 2699 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. Page 57 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 Page 2863 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) 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. Page 2867 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 Specifications Pressure Plate: Specifications Page 1888 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 Page 2038 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Page 291 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 With Caliper On Vehicle Brake Caliper: Testing and Inspection With Caliper On Vehicle Fig 8 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. Page 1937 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 Page 814 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. Page 3871 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. Page 1176 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. Page 2194 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. Page 311 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 Page 3493 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. 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. Page 216 Fig. 3 Speed control wiring diagram. 1981-84 Ramcharger, Trail Duster & Conventional Cabs Specifications Brake Disc: Specifications Nominal Thickness 1.24-1.25 in Minimum Thickness Note: Use minimum thickness specification stamped on rotor hub. Thickness Variation (Parallelism) 0.0005 in Runout (TIR) 0.004 in Finish 15-80 micro-in Page 4006 Trailer Lighting Module: Electrical Diagrams Fig. 45 Trailer Tow & Camper Wiring Circuit (Part 1 of 2). 1983-84 Fig. 45 Trailer Tow & Camper Wiring Circuit (Part 2 of 2). 1983-84 Page 3491 Fig. 10 Speed control wiring diagram. 1986 Mini-Vans/Wagons Fig. 83 Servo Terminal Electrical Connections Page 1697 *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 Page 298 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 Service and Repair 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. Page 54 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 Page 445 Crankshaft Position Sensor: Service and Repair Distributor Assembly 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. Page 1081 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. Page 3896 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. 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 Page 269 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 Page 3152 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 Page 1198 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). Diagram Information and Instructions EGR 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. Page 2861 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. Page 2879 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. Page 3777 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. Page 2660 Fig. 31 Four Wheel Drive Indicator Lamp Wiring Circuit. 1983-84 Page 3101 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. Page 2163 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). Page 2959 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 Page 3781 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 Page 2275 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). Page 3187 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. Page 1642 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* Page 2133 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. 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 Electrical Specifications Page 4011 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. Page 518 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). Page 2070 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 Page 1487 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. Page 2218 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Page 1333 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. Page 797 Crankshaft: Specifications Main Cap Torque Main Cap Torque Main Bearing Cap Bolts 85 ft.lb Page 1610 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 Page 1650 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. Page 967 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. Diagram Information and Instructions Trailer Lighting 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. Page 3181 11. Install seal cup using adapter C-4398-2, and driver C-4398-1. Use a small amount of wheel bearing grease on adapter face to hold cup in position, then drive cup until bottomed in knuckle. Do not remove tool at this time. 12. Apply a 1/4 inch bead of RTV sealer to retainer face on the chamfer. This replaces the O-ring discarded during disassembly. 13. Carefully remove seal installing tool from knuckle bore so that outer axle shaft remains centered. If shaft is moved, ensure that lip seal is still riding inside cup. Correct if necessary. 14. Before installing hub, rotor, retainer and bearing assembly on knuckle, position bearing retainer in hub so that grease fitting is facing forward, if equipped. Use a crossing method and torque retainer plate bolts to 30 ft-lbs. Bearing retainers that have a grease fitting must be positioned on knuckle so that fitting is facing directly forward. 15. Install brake adapter and remove any pry bar from universal joint. 16. Install axle shaft washer and nut. Torque nut to 100 ft-lbs. and continue to tighten nut until next slot in nut aligns with hole in axle shaft. Install cotter pin. 17. Through the access hole in hub, lubricate fitting in bearing retainer with multipurpose grease until grease flows through new inner seal. Seal may be viewed through universal joint area. Spin hub several times and lubricate fitting again. Grease must flow from 1/2 of seal diameter. 18. Replace brake caliper assembly and wheel, then lower vehicle and test operation. MODELS LESS FULL TIME 4WD Removal & Disassembly 1. Remove locking hub assembly, if equipped. 2. Raise vehicle and remove wheel assembly. 3. Remove caliper retainer and anti-rattle spring assemblies. 4. Remove caliper from disc and support caliper to prevent damage to brake line. 5. Remove the inboard brake pad and disc. 6. Remove the caliper adapter from knuckle. 7. Remove the six nuts and washers from spindle to steering knuckle attaching bolts. 8. Remove brake splash shield. 9. Tap spindle lightly with soft faced hammer to free from steering knuckle. 10. Upon removal, examine bronze spacer between needle bearing and shaft joint assembly. If wear is evident, replace. 11. Clamp spindle in vise avoiding bearing carrying surfaces. Remove needle bearing grease seal. 12. Using a suitable puller remover inner axle needle bearings. On 1985-87 models, left spindle does not have needle bearings. 13. Carefully remove axle shaft, axle seal and stone shield, if equipped. 14. Remove the tie rod from the steering knuckle. 15. On the left side only, remove drag link from steering knuckle. 16. On the left side only, remove the nuts and cone washers from steering knuckle arm. Tap the steering knuckle arm to free knuckle. Remove arm. 17. Remove cotter pin from upper ball joint nut. Remove upper and lower ball joint nut. Discard lower nut. 18. Using a brass drift and hammer separate steering knuckle from axle housing yoke. Remove sleeve from upper ball joint using tool C-4169. Discard sleeve. 19. Install steering knuckle in vise and remove snap ring from lower ball joint with suitable snap ring pliers. 20. Using tool C-4212-1 and adapter set C-4288, press lower ball joint from steering knuckle. 21. Reposition tool, and press upper ball joint from steering knuckle. Replace ball joints if any looseness or end play exists. Cleaning & Inspection 1. Clean all parts using a suitable solvent. 2. Blow dry parts using compressed air. 3. Inspect all parts for cracks, wear, chips, burrs and distortion. 4. Replace any parts not suitable for further service. Assembly & Installation 1. Position steering knuckle right side up in a vise. Using tool C-4212-1 and adapter set C-4288, press the lower ball joint into position. 2. Using the same tool and adapter set as above, install the upper ball joint. 3. Install new boots on the ball joints and remove the steering knuckle from the vise. 4. Screw a new sleeve into the upper ball joint yoke leaving two threads showing at the top. 5. Position steering knuckle on axle housing yoke and torque new lower ball joint nut to 80 ft-lbs. 6. Using tool C-4169 and a torque wrench, torque sleeve in upper ball joint to 40 ft-lbs. Install upper ball joint and torque to 100 ft-lbs. Align slot in nut with hole in stud and install cotter pin. Do not loosen to align. 7. On left side only, position steering knuckle arm over studs on steering knuckle. Install cone washers and nuts and torque to 90 ft-lbs. 8. Install drag link on steering knuckle arm and torque to 60 ft-lbs. Install cotter pin. 9. Install the rod end to steering knuckle. Torque nut to 45 ft-lbs. and install cotter pin. 10. Install lip seal on stone shield with lip toward axle shaft spline. 11. On all except 1986-87 left side, carefully insert axle shaft into housing. Avoid damaging differential seal at right side gear or axle shaft seal on left side gear. 12. On 1986-87 left side, proceed as follows: Page 3618 FIGURE 3C - BODY WIRING Page 1121 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. 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. Page 2880 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. Page 2317 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 Page 351 *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 Page 1169 FIGURE 3-A Specifications Vacuum Brake Booster: Specifications Power Brake assembly to dash ........................................................................................................... ........................................................ 220 in lb (25 Nm) Page 171 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. 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) Page 2700 Fig 7 Removing Or Installing Inboard 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 in lb (22.6 Nm). Fig 1 Disc Brake Assembly (Rear View) 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. 6. Bleed brakes. 7. Pump brake pedal several times until a firm pedal has been obtained. 8. After bleeding caliper, check for fluid tightness under maximum pedal pressures. (Recheck master cylinder reservoir level). 9. Install wheel and tire assembly. Tighten stud nuts. 10. Remove jackstands or lower hoist. 11. Road test vehicle and make several stops to wear off any foreign material on the brakes and to seat the linings. Page 1922 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 Page 3566 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. 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). Page 2306 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. Page 2285 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 Page 2110 *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 Page 1845 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 Page 2854 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. Page 2973 Fig. 7 Alternator & electronic voltage regulator diagnosis chart Page 2302 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. Page 2962 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 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: 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: 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. Page 3932 Fig. 7 Ash Tray, Cargo, Glove Box & Map Lamp Wiring Circuits. 1983-84 Page 2262 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 Page 92 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. Page 512 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). Halfshaft U-Joint Type Axle Shaft Axle Shaft: Service and Repair Halfshaft U-Joint Type Axle Shaft Spicer 44FBJ & 44-8FD Front Axle 1980-84 Removal 1. Remove locking hub assembly from vehicle. 2. Raise and support vehicle. 3. Remove tire and wheel assembly. 4. Remove caliper retainer and anti-rattle spring assemblies. Remove caliper from disc by sliding outward and away from disc. Hang caliper away from assembly. Do not allow caliper to hang or be supported by the brake lines. 5. Remove inboard shoe. 6. Remove outer axle shaft locknut washer and nut assembly. 7. Remove rotor and bearing assembly. 8. Remove six nuts attaching splash shield and spindle to knuckle assembly, if equipped. 9. Remove splash shield and spindle. 10. Remove brake caliper adapter from knuckle. 11. Carefully remove axle shaft assembly. Remove seal and stone shield from shaft. Installation 1. Install lip seal on axle shaft stone shield with lip of seal toward axle shaft spline. 2. Carefully insert axle shaft into housing. 3. Install spindle and brake splash shield. Install the six nuts and torque to 25-30 ft-lbs. 4. Install rotor, outer bearing nut, washer and locknut on spindle. 5. Install brake adapter and torque to 85 ft-lbs. 6. Install inboard brake shoe on adapter with shoe flanges located in adapter keyways. Slowly slide caliper assembly into position in adapter. 7. Install anti-rattle springs and retaining clips. Torque to 180 inch lbs. 8. Install locking hub assembly. 9. Install tire and wheel assembly. Torque attaching nuts to 110 ft-lbs. Removal Fig. 19 Removing snap ring. 60 Front Axle Fig. 20 Removing hub lock nut. 60 Front Axle Diagram Information and Instructions Multiple Junction Connector: 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. Page 131 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. Page 611 FIGURE 3-A 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. Page 2076 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 Page 3533 Fig. 4 Speed control wiring diagram. 1982-84 Rampage & 1983 Scamp Page 3647 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. Page 3464 Fig. 9 Speed control wiring diagram. 1986 rear wheel drive Ram Van & Wagons Page 2960 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 Page 3470 Fig. 3 Speed control wiring diagram. 1981-84 Ramcharger, Trail Duster & Conventional Cabs Page 3602 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 Page 2034 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. 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. Page 2340 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. 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. 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. Auto Locking Hubs - Not Locking/Unlocking Wheel Hub (Locking): Customer Interest Auto Locking Hubs - Not Locking/Unlocking Models 1981-1984 "W" Model Trucks Equipped With Automatic Locking Hubs Subject Automatic Locking Hubs Will Not Operate During Low Temperatures Index FRONT SUSPENSION Date October 28, 1985 No. 02-10-85 SYMPTOM/CONDITION Customer concern of automatic locking hubs not locking/unlocking during below freezing weather. DIAGNOSIS Road test the vehicle and check for hubs locking/unlocking. NOTE: IF AMBIENT TEMPERATURES ARE ABOVE FREEZING, THE HUBS MAY OPERATE PROPERLY, THEN VISUAL INSPECTION IS REQUIRED. REMOVE THE COVER FROM THE HUB. INSPECT THE HUB FOR THE PRESENCE OF WATER CONTAMINATION. THIS WILL APPEAR IN THE FORM OF DISCOLORED GREASE OR RUST. If the hub is water contaminated, perform the following operation: PARTS REQUIRED Hub Repair Package PN 4411998 (as required) REPAIR PROCEDURE 1. Remove hub from axle. 2. Inspect the hub carefully to determine the extent of the water damage. If the hub components are corroded beyond repair, replace the hub assembly with new hub, PN 4384120. If damage to the hub is light, do the following: 3. Disassemble the hub and clean thoroughly to remove all contaminants Refer to Rear Wheel Drive Truck Service Manual for service procedure. 4. Inspect all components, especially the drag sleeve, brake band, and inner and outer cages for damage. Replace as necessary. 5. Reassemble the hub. 6. Lubricate the hub by dipping all components except the bearing and race assembly, brake band, and drag sleeve assembly in automatic transmission fluid. 7. Allow the excess transmission fluid to drip off. 8. Repack the bearing and race assembly with Darmex Lubricant, PN 4293040. 9. Lubricate the brake band and drag sleeve with Darmex Lubricant, PN 4293040. IMPORTANT: DO NOT SUBSTITUTE ANY OTHER LUBRICANT FOR THE DARMEX LUBRICANT SPECIFIED IN STEPS 8 AND 9, OR FAILURE OF THE HUB TO OPERATE PROPERLY COULD RESULT. 10. Reassemble and install the hub as outlined in the service manual. Page 2448 Crankshaft Position Sensor: Service and Repair 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. 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: 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. Specifications Power Window Circuit Breaker: Specifications Power Window Circuit Breaker Specification ..................................................................................................................................................... 30 amps Page 857 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 Page 1434 Crankshaft Position Sensor: Service and Repair 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. 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: Page 2031 FIGURE 3C - BODY WIRING Removal & Installation Crankshaft Position Sensor: Service and Repair 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. Locations Page 1211 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* Page 988 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. Page 306 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). Page 2751 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. Page 328 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). Page 1539 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. Page 1889 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 Page 2227 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 Page 612 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. Page 641 Fluid - A/T: Specifications Initial Refill Capacity TYPE.................................................................................................................................................... ...........................................................................AP** CAPACITY, Initial Refill*: All models w/o torque converter drain...............................................................................................................................................3.8 Liters 4.0 Quarts *With the engine at operating temperature, shift transmission through all gears. Check fluid level in NEUTRAL and add fluid as needed. **May use AF or MA when AP is not available only for "Topping off". Page 1696 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* Page 511 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) Page 1931 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 Page 1178 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 Page 1520 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 Page 1209 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. Page 352 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 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. Page 3005 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. Page 2229 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. Page 805 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. Page 3536 Fig. 7 Speed control wiring diagram. 1985 rear wheel drive Ram Van & Wagons Page 2808 Fig 14 Installing Piston Seal 1. Clamp caliper in vise (with protector jaws). CAUTION: Excessive vise pressure will cause bore distortion and binding of piston. 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. 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: Page 3539 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. Page 1837 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. 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, Page 2307 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. Page 3548 Fig. 8 Speed control wiring diagram. 1986-87 Conventional Cabs & Ramchargers Diagram Information and Instructions Intake Air Temperature 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. 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. Page 1451 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. Page 210 Fig. 9 Speed control wiring diagram. 1986 rear wheel drive Ram Van & Wagons Page 880 Fig. 37 Oil Lamp With Gauge Cluster Wiring Circuit. 1984 Locations Distributor Vacuum Control: Locations Orifice Spark Advance Control (OSAC) Valve Location. In Air Cleaner Housing Applicable to: V8 Engine Page 3164 Fig. 4 Exploded view of Chrysler Constant Control power steering gear Fig. 5 Reaction seal removal Locations EGR Valve: Locations Exhaust Gas Recirculation (EGR) System Components Upper LH Side Of Engine Page 47 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 Page 1133 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 Page 3547 Fig. 7 Speed control wiring diagram. 1985 rear wheel drive Ram Van & Wagons Page 763 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. 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. Page 1609 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 Page 3849 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 Page 2172 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. Specifications Page 2138 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). Page 2318 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 Page 1684 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Diagram Information and Instructions Oil Pressure Gauge: 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. Page 1598 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). Specifications Door Lock: Specifications Power Door Lock Circuit Breaker Specification ................................................................................................................................................. 30 amps Page 64 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. 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). 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 Page 1136 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). Page 2109 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* Page 1905 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. Locations Circuit Breaker: Locations Door Lock And Power Window Circuit Breaker And Relays Location The circuit breaker is located behind the dash panel, to the left of the glove box. Page 1142 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. Page 949 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. Page 285 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Auto Locking Hubs - Not Locking/Unlocking Wheel Hub (Locking): Customer Interest Auto Locking Hubs - Not Locking/Unlocking Models 1981-1984 "W" Model Trucks Equipped With Automatic Locking Hubs Subject Automatic Locking Hubs Will Not Operate During Low Temperatures Index FRONT SUSPENSION Date October 28, 1985 No. 02-10-85 SYMPTOM/CONDITION Customer concern of automatic locking hubs not locking/unlocking during below freezing weather. DIAGNOSIS Road test the vehicle and check for hubs locking/unlocking. NOTE: IF AMBIENT TEMPERATURES ARE ABOVE FREEZING, THE HUBS MAY OPERATE PROPERLY, THEN VISUAL INSPECTION IS REQUIRED. REMOVE THE COVER FROM THE HUB. INSPECT THE HUB FOR THE PRESENCE OF WATER CONTAMINATION. THIS WILL APPEAR IN THE FORM OF DISCOLORED GREASE OR RUST. If the hub is water contaminated, perform the following operation: PARTS REQUIRED Hub Repair Package PN 4411998 (as required) REPAIR PROCEDURE 1. Remove hub from axle. 2. Inspect the hub carefully to determine the extent of the water damage. If the hub components are corroded beyond repair, replace the hub assembly with new hub, PN 4384120. If damage to the hub is light, do the following: 3. Disassemble the hub and clean thoroughly to remove all contaminants Refer to Rear Wheel Drive Truck Service Manual for service procedure. 4. Inspect all components, especially the drag sleeve, brake band, and inner and outer cages for damage. Replace as necessary. 5. Reassemble the hub. 6. Lubricate the hub by dipping all components except the bearing and race assembly, brake band, and drag sleeve assembly in automatic transmission fluid. 7. Allow the excess transmission fluid to drip off. 8. Repack the bearing and race assembly with Darmex Lubricant, PN 4293040. 9. Lubricate the brake band and drag sleeve with Darmex Lubricant, PN 4293040. IMPORTANT: DO NOT SUBSTITUTE ANY OTHER LUBRICANT FOR THE DARMEX LUBRICANT SPECIFIED IN STEPS 8 AND 9, OR FAILURE OF THE HUB TO OPERATE PROPERLY COULD RESULT. 10. Reassemble and install the hub as outlined in the service manual. 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. Page 3073 Fig. 27 Engine Compartment ECU Ignition Wiring Circuit. 1983-84 W/V8 Engine Page 2063 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. Locations Circuit Breaker: Locations Door Lock And Power Window Circuit Breaker And Relays Location The circuit breaker is located behind the dash panel, to the left of the glove box. Specifications Page 2154 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). Page 1184 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 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. Page 2379 TIMING MARK 1981-90 Some 5.2L & 5.9L Page 3506 Fig. 7 Speed control wiring diagram. 1985 rear wheel drive Ram Van & Wagons Page 283 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). Page 2499 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. Specifications Connecting Rod: Specifications Connecting Rod Cap Bolts 45 ft.lb 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) Page 2999 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. Page 1481 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 Page 2178 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 Page 1803 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. Page 1355 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 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. 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 Page 1509 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. Page 1942 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. Page 3538 Fig. 9 Speed control wiring diagram. 1986 rear wheel drive Ram Van & Wagons Page 1118 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 Page 3802 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Page 3260 11. Install new cover and screws with "O" rings, PN 4411998. 12. Torque the cover screws to 40-50 inch pounds (4.5 - 5.6 N-m). 13. Check the hubs for locking/unlocking. POLICY: Information only Page 1687 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. Page 310 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. Page 3841 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 Radio - Speaker Noise When Warning Buzzers Are ON Seat Belt Reminder Buzzer: Customer Interest Radio - Speaker Noise When Warning Buzzers Are ON Models 1984 Vehicles Equipped With Standard AM/FM (Sales Code RAL) Radio Subject Radio Noise From Warning Buzzer on AM Band Index ELECTRICAL Date November 23, 1984 No.. 08-26-84 P-4992 SYMPTOM/CONDITION Subject vehicles may exhibit excessive noise on the AM band when seat belt, headlamp on, key in warning buzzer is operated. REPAIR PROCEDURE Replace Warning Buzzer, PN 3747751, (grey case) with new Suppressed Warning Buzzer, PN 4221730, (green case). Verify operation of all buzzer functions. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Refer to Labor Operation Time Schedule for Labor Operation and Time Allowance. Page 1354 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 Page 1537 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. Page 1661 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. Page 2705 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. Diagram Information and Instructions Oil Pressure Gauge: 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. 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. Page 1603 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 Page 2343 *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 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. 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. Specifications Compression Check: Specifications Compression Check Specifications Compression Check Specifications Compression Pressure 100 psi At cranking speed, engine temperature normalized, throttle open Maximum Variation 40 psi Page 2333 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. Page 1523 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). Page 3632 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. Page 3074 Fig. 29 Engine Compartment Electronic Spark Advance (W/Feedback Carburetor, Part 1 of 3) Wiring Circuit. 1983-84 Page 2040 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. Page 2205 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 Page 1450 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. Page 3270 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. Page 907 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. Page 3693 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. Page 3157 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 Page 2216 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). Page 3510 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. 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. Page 2963 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 Page 1157 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* Page 3623 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). Page 2701 - The vehicle may pull to one side or the other if this is not done. Page 1489 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. Page 2042 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 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. Page 3486 Fig. 5 Speed control wiring diagram. 1984 Mini-Vans/Wagons (1985 similar) Page 81 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* Page 1981 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) Page 597 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. Diagram Information and Instructions Oil Pressure Warning Lamp/Indicator: 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. 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. Page 2069 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. Page 972 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 Page 980 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). 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. Page 2331 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Page 3805 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. Page 890 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. 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: Page 3778 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. Page 349 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. Page 1662 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 Page 2219 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS Page 1148 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. Page 1774 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. Page 3155 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 Page 3715 Fig. 2 Printed Circuit Board. 1983-84 Page 1168 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. Rear Axle Shaft Oil Seal - Update Axle Shaft: Technical Service Bulletins Rear Axle Shaft Oil Seal - Update Models All 1984 Rear Wheel Drive Domestic Vehicles Equipped With 7-1/4, 8-1/4, 9-1/4 (Std.) Axle Subject New Rear Axle Shaft Oil Seal Index REAR AXLE Date November 19, 1984 No. 03-03-84 P-5121-C A new Axle Shaft Oil Seal, PN 4137426, was incorporated into all 7-1/4, 8-1/4, and 9-1/4 (standard) axles during April, 1984. The new seal replaces the old seal, PN 2931875, in all of these applications, and will service prior model year applications. The new seal features a flange which insures installation to the proper depth, and incorporates a sealant on the outside diameter. These features provide improved sealing. The new seal can be installed by using existing Miller Special Tool. Use Miller Special Tool #C-4202 and handle #C-4171 to install the seal. Turn Tool #C-4202 so that the flat side is against the seal. Drive the seal flange flush with the axle housing. CAUTION: DO NOT USE SPECIAL SERVICE TOOL #C-4130 CALLED OUT IN THE SERVICE MANUALS, AS THE FLANGE WILL BE DAMAGED AND AN OIL LEAK MAY RESULT. THE CURRENT SEAL, PN 2931875. WILL CONTINUE TO BE USED FOR SERVICE UNTIL THE NEW SEAL, PN 4137426, IS AVAILABLE FOR SERVICE. POLICY: Information only Page 1513 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 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 Page 1167 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). Removal & Installation Crankshaft Position Sensor: Service and Repair 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. Page 466 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. Page 44 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. Page 2089 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. Page 889 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. Page 2696 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. Page 2231 *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 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. Page 2955 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. Page 1651 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) Page 1770 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. Page 3823 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) Page 409 Manifold Pressure/Vacuum Sensor: Locations Combustion Control Computer Location. Upper RH Side Of Engine Applicable to: 1981-84 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. Page 3520 Fig. 3 Speed control wiring diagram. 1981-84 Ramcharger, Trail Duster & Conventional Cabs Page 2265 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. Diagrams Page 1969 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. Page 3103 18. Install drive shaft key in slot in shaft. Support shaft on opposite side while installing key. Install reservoir cap. Page 2221 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. Page 1627 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. Page 315 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. Page 2634 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. Locations Transmission Pressure Test Port: Locations Specifications Refrigerant Oil: Specifications Capacities Capacities Capacity Viscosity 9-10 oz (US) 500 Page 1512 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 Page 965 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 Page 3392 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. Page 2487 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. Page 3892 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. Page 2763 - 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. Page 1695 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. Page 332 FIGURE 3C - BODY WIRING Specifications Fluid - M/T: Specifications A833 OD............................................................................................................................................... .......................................................................AF, AP 75W, 75W-80, 80W-90, 85W-90, 90 GL-5 may be used NP435.......................................................... ......................................................................................................................................................GL-5 , SF, SG SF, 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 CAPACITY, Refill: NP435.................................. .............................................................................................................................................................. ....3.3 Liters 7.0 Pints A833 OD............................................................................................................................................... ................................................3.5 Liters 7.5 Pints 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. Page 610 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. 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. 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. Page 2185 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) Page 20 Trailer Lighting Module: Electrical Diagrams Fig. 45 Trailer Tow & Camper Wiring Circuit (Part 1 of 2). 1983-84 Fig. 45 Trailer Tow & Camper Wiring Circuit (Part 2 of 2). 1983-84 Page 3782 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 Specifications 4 Barrel Carburetor Page 2852 Brake Master Cylinder: Description and Operation 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. Page 68 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). Page 1892 (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). Page 2071 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). Page 2171 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 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 Page 2067 FIGURE 3-A Page 1632 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 Page 3856 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM 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. 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. Testing and Inspection 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. Locations Choke Pull-off: Locations Engine Mounted Switches & Sensors. RH Side Of Engine Applicable to: 6 Cylinder Engine Page 2174 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. Page 2891 pedal is required. Page 2766 Brake Drum: Service and Repair Brake Drum Installation For additional information see Notes, Warnings, and Hints. 1. Install brake drum. 2. Install wheel and tire assembly. 3. Adjust brakes. NOTE: Reinstallation of retaining clips is not necessary. Page 125 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 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. Service and Repair 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 Page 1149 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. 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. Page 3182 a. Remove disconnect housing cover, then position shift collar onto splined end of inner axle shaft. b. Install intermediate axle shaft through axle shaft seal. Use caution not to damage seal. c. Install disconnect housing cover assembly and gasket. Ensure shift fork is guided into groove of shift collar. d. Install disconnect cover shield and shield attaching bolts. Torque bolts to 10 ft-lbs. e. Connect vacuum lines and switch electrical connector. 13. Using tools D-122 and C-4171, install new needle bearings into spindle. 14. Fill seal area with NLGI grease or equivalent, and install seal with tools D-155 and C-4171. 15. Install new bronze spacer on axle shaft, install spindle and brake splash shield. 16. Install new nuts and torque to 25-35 ft-lbs. 17. Mount braking disc assembly and outer wheel bearing cone onto spindle. 18. Install wheel bearing nuts and locking washer. 19. Install locking hub assembly. 20. Install brake adapter and torque attaching bolts to 85 ft-lbs. 21. Install the assembled brake caliper assembly. 22. Install the wheel and torque the nuts to 110 ft-lbs. Lower vehicle and test operation. 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. Page 2168 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. Page 1698 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 Page 217 Fig. 4 Speed control wiring diagram. 1982-84 Rampage & 1983 Scamp Page 3115 Fig. 2 Steering column coupling & shaft adjustment. Motor Home Tilt Column Release Pedal Adjustment 1. Loosen pedal assembly locknut at adjustable mounting bracket assembly. 2. Move column adjusting assembly foot pad rearward, toward the driver, 0.040 inch from center line of rear column adjustable mounting bracket bolt. While holding pedal in this position, tighten nut until column is locked securely. 3. Test operation of column adjusting pedal by depressing and releasing several times. If correctly adjusted, the pedal will return to the approximate position shown. RAMCHARGER, TRAILDUSTER & D/W-100 THRU 400 SERIES Removal 1. Disconnect battery ground cable. 2. On vehicles with automatic transmission column shift, disconnect shift rod at lower end of column by prying grommet out of shift lever. A new grommet should be used whenever the rod is disconnected. 3. Remove coupling roll pin at lower end of column. 4. Disconnect electrical connectors at steering column jacket. 5. Remove steering wheel using a suitable puller. Do not attempt to remove steering wheel using a hammer as damage to the steering column and shaft will result. 6. Remove turn signal lever, then the floor plate to floor pan attaching nuts. 7. On 1980 models, remove cluster bezel. 8. Remove panel lower reinforcement. 9. On 1981 - 87 models, disconnect automatic transmission shift indicator cable from bracket on column. 10. Remove steering column bracket to instrument panel support nuts. 11. Disconnect coupling from steering gear worm shaft and remove steering column. Installation For installation, refer to the "Vans & Wagons Except Front Wheel Drive" procedure, however, torque steering wheel nut to 60 ft lb on 1980 - 82 models or 45 ft lb on 1983 - 87 models. Disassembly Page 1932 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. Page 2951 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 Locations Page 1669 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 Locations Detonation (Knock) Sensor: Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Page 2095 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). Page 3334 Trailer Connector: Electrical Diagrams Fig. 45 Trailer Tow & Camper Wiring Circuit (Part 1 of 2). 1983-84 Fig. 45 Trailer Tow & Camper Wiring Circuit (Part 2 of 2). 1983-84 Page 532 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). Page 2281 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 Page 1453 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). Page 2954 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. 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. Page 3853 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. Locations Trailer Lamps: Locations Circuit Location Amps Headlights.....................Integral With Switch..............20 Trailer Towing................Fuse Panel.........................6 Windshield Wipers.............Integral With Switch..............20 Description and Operation Catalytic Converter: Description and Operation Fig. 12 Typical catalytic converter Page 2010 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 Page 2676 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. Page 3393 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. Page 3124 Fig. 8 Steering column exploded view. Motor Home MOTOR HOME Disassembly 1. Clamp column assembly in a vise. 2. Remove turn signal lever, then remove turn signal switch retaining screws and lift switch up and position aside. 3. Remove snap ring from upper end of steering shaft. 4. Remove the 3 bearing housing retaining screws. These screws must be removed before steering shaft is removed. 5. Install tool C-4044 or equivalent, and press shaft out of bearing, then remove bearing housing from shaft. 6. Remove bearing lower snap ring from shaft, then remove shaft through lower end of column. 7. Place ignition switch lock cylinder in Lock position and remove key. Insert a small screwdriver into lock cylinder release hole and push in to release spring loaded lock retainer. Pull out lock cylinder and remove ignition switch. 8. Remove the 4 lock housing-to-column jacket hex head retaining screws and remove both housing and spring washer from jacket. Inspection 1. Clean all parts in suitable cleaning solvent and inspect parts. 2. Inspect turn signal switch for distortion or broken parts or damaged parts. Inspect wiring harness for worn or bare spots. 3. Inspect steering shaft bearing for smooth operation. If bearing shows any signs of roughness or wear, it should be replaced. Reassembly 1. Install boot and floor plate on lower end of column jacket. 2. Install spring washer and both housings. 3. Position ignition switch in center detent (Off) position. Feed wires down through the space between housing and jacket. Position switch in housing and tighten the 3 retaining screws. 4. With ignition key cylinder in Lock position, remove key. Insert cylinder into housing, then press cylinder until contact is made with pin on ignition switch cam. Insert key into lock and rotate until slot in cylinder plate aligns with pin. Press cylinder in the remaining way, making sure retainer bar snaps into its slot in lock housing. 5. Insert steering shaft assembly into column, then install bearing lower snap ring on shaft. 6. Place rubber insulator with ground staple over column upper bearing and install assembly into housing bore. Use lubricant to ease installation. 7. Install turn signal switch, while feeding the wires through the opening in the housing, then install retaining plate and torque the 3 retaining screws to 27 inch lbs. 8. Install turn signal lever and torque retaining screw to 30 inch lbs. 9. Place bearing housing assembly on column jacket assembly, while feeding wires through space between lower housing and jacket. Install wire cover trough. 10. Using tool C-3879 or equivalent, washer and nut, install housing onto steering shaft. Remove tool and install snap ring. 11. Install the 3 bearing housing to lock housing screws and torque to 35 inch lbs. Page 2724 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. 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. Page 2026 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. Specifications Flywheel: Specifications Flywheel to Crankshaft Bolts 55 ft.lb Page 984 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. Page 1689 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 Locations Clutch Switch: Locations On Clutch Pedal Page 1790 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. Page 323 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 Page 3724 FIGURE 4 10. Before inserting replacement odometer chip into cluster (or transferring existing odometer chip to new cluster), inspect pins of chip to assure they are straight and perpendicular to chip body. If not, align pins before attempting to install in cluster (Figure 4). 11. The odometer chip should now be placed lightly in the socket with the notch to the left. Note that each of the 14 contact pins is in contact with the lip of the socket pin. If all 14 pins are not started in the socket, gently reform the pins to match the socket holes. Press the odometer chip into position with Miller Special Tool #C-4817. 12. Verify that the odometer chip notch is toward the left when the cluster is face down, and bottom of cluster is toward installer. 13. Replace access door and install cluster in vehicle per service manual procedures. 14. If odometer chip was transferred to new cluster or original mileage odometer chip was obtained, verify that the mileage is the same as was recorded. This bulletin is released in advance of parts availability. The parts listed in this bulletin will be available in mid-March, 1984. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 08-70-02-01 Memory Chip With Zero Mileage 0.4 Hrs. 08-70-02-02 Memory Chip With Original Mileage 0.4 Hrs. FAILURE CODE: 58 - Internal Defect Page 3126 Fig. 11 Non-tilt wheel steering column exploded view (column shift auto. trans.) Ramcharger, Trailduster & W/D-100 thru 400 series Fig. 12 Non-tilt wheel steering column exploded view (floor shift man. trans.) Ramcharger, Trailduster & W/D-100 thru 400 series EXCEPT MINI-VANS/WAGONS, MOTOR HOME, RAMPAGE & SCAMP DISASSEMBLY Shift Lever, Turn Signal Switch & Lamp Assembly 1. Pry out wiring trough retainers and lift off wiring trough. 2. Using a suitable punch, drive out shift lever roll pin. Use a deep socket to accept the roll pin as it is driven out. 3. Place steering column in a vise by securing it at the bracket. 4. Remove turn signal switch and upper bearing retaining screws, then remove retainer and lift switch up and out of the way. 5. Remove retaining screw and lift off ignition key lamp assembly up and out of the way. Page 3508 Fig. 9 Speed control wiring diagram. 1986 rear wheel drive Ram Van & Wagons Page 2004 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) Page 2702 Brake Caliper: Service and Repair Disassembly and Assembly Disassembly Fig. 11 Piston Seal Removal 1. To remove piston, support caliper assembly on steering knuckle on shop towels to absorb any hydraulic fluid loss. 2. Carefully depress brake pedal to hydraulically push piston out of bore (brake pedal will fall away when piston has passed bore opening) 3. 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. 4. 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. 5. Disconnect brake flexible hose from the caliper. 6. Mount caliper assembly in a vise equipped with protector jaws. CAUTION: Excessive vise pressure will cause bore distortion and binding of piston. 7. Remove dust boot using suitable tool. 8. Using a small, pointed, wooden or plastic rod, 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 Page 3648 FIGURE 3-A Page 60 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). Page 228 Fig. 4 Speed control wiring diagram. 1982-84 Rampage & 1983 Scamp Page 2157 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 Page 888 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. 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. Page 1635 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 Page 3552 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. Specifications With Caliper On Vehicle Brake Caliper: Testing and Inspection With Caliper On Vehicle Fig 8 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. 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: Page 1137 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. 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. Locations Choke Temperature Control Switch: Locations Upper RH Side Of Engine Page 223 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. Testing and Inspection 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 Page 982 FIGURE 3-A 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. Page 2326 FIGURE 3D - BODY WIRING Page 208 Fig. 7 Speed control wiring diagram. 1985 rear wheel drive Ram Van & Wagons Page 102 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 Page 3484 Fig. 3 Speed control wiring diagram. 1981-84 Ramcharger, Trail Duster & Conventional Cabs Page 2310 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 KM-144 M/T - Shift Pattern Change Shift Linkage: Technical Service Bulletins KM-144 M/T - Shift Pattern Change Models 1984 Power Ram 50 Four Wheel Drive Pick-Up Equipped With KM-144 Transmission Subject Change in Shift Pattern of KM-144 Manual Transmission Index TRANSMISSION Date January 2, 1985 No. 21-01-85 FIGURE 1 - Shift Pattern The shift pattern for the KM-144 transmission was to improve shift effort (Figure 1). As a result of the pattern change, the following parts were also affected. 1. Shift Pattern The shift pattern was changed as illustrated (Figure 1). The return force is applied in the direction of arrow. 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. Page 1941 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 Page 1550 Engine Control Module: Locations Engine Control Module Combustion Control Computer Location. Upper RH Side Of Engine Applicable to: 1981-84 Page 2100 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. 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. Page 2084 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 Page 3684 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. Page 1873 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. In-Line Mounted Booster Vacuum Brake Booster: Service and Repair In-Line Mounted Booster INLINE MOUNT 1. Disconnect vacuum hose from check valve. 2. Remove master cylinder to booster attaching nuts. 3. Working from under instrument panel, position a suitable screwdriver between center tang on retainer clip and pin in brake pedal. Rotate screwdriver enough to allow retainer clip center tang to pass over end of brake pedal pin, then pull retainer clip from pin. 4. Remove power booster attaching nuts, then slide booster away from dash panel. 5. Reverse procedure to install. Engine - Valve Train Noise Rocker Arm Assembly: Customer Interest Engine - Valve Train Noise Models 1984 Rear Wheel Drive Passenger Car Equipped W/318 Engine; 1984 Rear Wheel Drive Truck & Vans Equipped W/318 or 360 Engine Subject Valve Rocker Arm Breakage Index ENGINE Date December 21, 1984 No.. 09-11-84 SYMPTOM/CONDITION Noise in valve train. DIAGNOSIS Remove valve cover and inspect rocker arms for breakage in the push rod area. The push rod may have penetrated the rocker arm. PARTS REQUIRED Passenger Car & Truck 8 - Rocker Arm PN 4100774 8 - Rocker Arm PN 4100775 REPAIR PROCEDURE When a rocker arm is found to have failed in the above manner in the subject model engines, it is necessary to replace all 16 rocker arms and inspect the push rods. 1. Remove valve covers. 2. Remove all rocker arms and replace with new ones. 3. Inspect push rods and replace as necessary. 4. Reinstall rocker shafts and torque screws to 25 foot pounds (34 N-m). 5. Replace valve cover gaskets and reinstall valve covers. Tighten valve cover screws to 80 inch pounds (9 N-m). POLICY: Information only Page 517 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 Page 2330 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Page 617 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. Page 671 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. 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. Page 1714 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine 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. Page 1511 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 Page 397 Crankshaft Position Sensor: Service and Repair Distributor Assembly 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. Diagnostic Trouble Code Descriptions Information Bus: Diagnostic Trouble Code Descriptions For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes Page 129 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. 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. Page 3829 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 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). Page 510 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. Page 3041 Fig. 27 Engine Compartment ECU Ignition Wiring Circuit. 1983-84 W/V8 Engine Page 2161 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. Page 1200 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS 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. Page 1674 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). Page 276 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. Page 2971 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 Page 1368 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. 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, Page 443 Crankshaft Position Sensor: Service and Repair 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. 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: Page 4031 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. 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. Specifications Exhaust Manifold: Specifications Manifold Fastener Torque Manifold Fastener Torque Exhaust Manifold Screws 20 ft.lb Nuts 15 ft.lb Page 3860 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. Page 618 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. Page 3592 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). Page 1624 FIGURE 3C - BODY WIRING Locations Page 2620 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. Page 3149 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 Locations Oxygen Sensor: Locations Engine Mounted Switches & Sensors. Lower RH Side Of Engine Applicable to: V8 Engine Page 2051 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 Page 3460 Fig. 5 Speed control wiring diagram. 1984 Mini-Vans/Wagons (1985 similar) Page 663 Refrigerant: Fluid Type Specifications A/C Refrigerant Specifications A/C Refrigerant Specifications Refrigerant Types R-12 Choke Heater Electric Assist Choke: Locations Choke Heater Engine Mounted Switches & Sensors. Page 1452 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 Differentials Fluid - Differential: Specifications Differentials Above 90°F (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....................................................... ..........................................................................................................................................................G L-5 CAPACITY, Refill: Front: 4-wheel drive Spicer 60F....................................................................... ....................................................................................3.1 Liters 6.5 Pints Others................................................................................................................................................... ...............................................1.7 Liters 3.5 Pints Rear: Spicer 60, 60 HD........................................................................................................................ ................................................2.8 Liters 6.0 Pints Spicer 70.............................................................................................................................................. ................................................3.1 Liters 6.5 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 the ground, turn one wheel & other will rotate in same direction Page 2255 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 Page 1608 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 Page 1534 FIGURE 8 - ELECTRIC FUEL PUMP WIRING DIAGRAM W/AUX. A/C & HEATER AND POWER WINDOWS 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. Page 2327 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. Locations Clutch Switch: Locations On Clutch Pedal Locations Choke Temperature Control Switch: Locations Upper RH Side Of Engine Page 2610 5. Lubricate splines with automatic transmission fluid. 6. Reinstall driveshaft. 7. Lower vehicle and road test. POLICY: Reimbursable within the provisions of the warranty TIME ALLOWANCE: Labor Operation No. 16-30-10-01................................ 0.6 Hrs. Refer to Labor Operation Time Schedule FAILURE CODE: 52 - Improperly Machined Page 172 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 support bracket. Install by attaching relay to the instrument panel support bracket and connecting the wires to the relay. Connect the battery negative terminal and test the system for proper operation. Page 3671 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 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. Page 346 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. Page 2274 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). Page 3863 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 Specifications Fig. 4 Fusible Link Connector. 1983-84 Page 37 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). Page 2850 Brake Master Cylinder: Specifications Master Cylinder to Booster ............................................................................................................................................................ 170-230 in lb (22.5 Nm) Page 2494 Fluid - A/T: Specifications Initial Refill Capacity TYPE.................................................................................................................................................... ...........................................................................AP** CAPACITY, Initial Refill*: All models w/o torque converter drain...............................................................................................................................................3.8 Liters 4.0 Quarts *With the engine at operating temperature, shift transmission through all gears. Check fluid level in NEUTRAL and add fluid as needed. **May use AF or MA when AP is not available only for "Topping off". Diagram Information and Instructions Oil Pressure Warning Lamp/Indicator: 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. Page 2858 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. Page 2787 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. Page 2725 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 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. 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 Page 3822 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. Page 906 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. Page 1980 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. Page 2046 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 Page 2198 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 Page 449 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. Driveline - Clunk or Snap on Acceleration or Braking Slip Yoke: All Technical Service Bulletins Driveline - Clunk or Snap on Acceleration or Braking Models 1981-1984 D100, 150, 200, 250, Two-Wheel Drive Pick-Up Truck, B 100, 150, 200, 250, Ram Vans, Wagons & Voyagers Subject Driveline "Clunk" or "Snap" Index PROP SHAFT & U JOINTS Date 11/12/84 No.. 16-01-84 P-5035C This bulletin supersedes and cancels Technical Service Bulletin #16- 02-83, which should be removed from your files. This bulletin eliminates the need to replace the complete driveshaft assembly in two wheel drive trucks are described in Technical Service Bulletin #16-02-83. Four wheel drive models will be addressed in a future bulletin. SYMPTOM/CONDITION Customer concern for a "snap" or "clunk" after medium-heavy brake application to a stop is completed or when accelerating from a stop. The noise may also be heard 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 nose 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 slip yoke in the transmission extension. At the end of the stopping maneuver, the slip yoke would ordinarily slide smoothly back into the extension. The characteristic "snap" occurs when the slip yoke momentarily binds in the rearward position, then abruptly "snaps" forward to the neutral position. PARTS REQUIRED Vehicles equipped with A904/999 transmission: 1 - Yoke (nickel plated) PN 4137452 Vehicles equipped with A727 transmission: 1 - Yoke (nickel plated) PN 4137456 REPAIR PROCEDURE 1. Raise vehicle. 2. Remove driveshaft. 3. Remove slip yoke. 4. Install nickel plated slip yoke on driveshaft. Page 1678 FIGURE 3C - BODY WIRING Specifications Valve Cover: Specifications Valve Cover Bolts 80 in.lb Page 236 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. Page 262 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 Page 1363 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) Page 515 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. Page 2900 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 Page 3091 Fig. 12 Using driving & adapter to install seal cup into knuckle. 44 FBJ Units w/disc brakes. Models w/full time 4WD Fig. 13 Tools in place after seal cup is installed. 44 FBJ Units w/disc brakes. Models w/full time 4WD Fig. 15 Forming a seal on bearing retainer face. 44 FBJ Units w/disc brakes. Models w/full time 4WD Fig. 16 Bearing retainer positioned with grease fitting facing forward. 44 FBJ Units w/disc brakes. Models w/full time 4WD Page 1048 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Page 2344 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 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. 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. Locations Temperature Sensor (Gauge): Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Page 2984 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. Page 2786 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. Page 2801 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. 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. Page 1985 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. Page 2559 Fig. 21 Removing or replacing axle shaft. 60 Front Axle Fig. 22 Removing or replacing upper socket pin. 60 Front Axle 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. Page 3859 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. 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. 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. Page 1348 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. 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: Page 940 LABEL SPECIFICATIONS, TYPE IN ON THE RIGHT HAND SIDE OF THE LABEL "REFER TO ORIGINAL VECI LABEL". IN EVERY CASE WHERE THIS LABEL IS USED, TYPE IN AFTER - AUTHORITY OF TECHNICAL SERVICE BULLETIN #25-05-84, AND YOUR DEALER CODE BELOW. LABEL PN 4275084 IS AVAILABLE FROM PARTS SUPPLY. Conversion Procedure 1. On the 360-4V only, replace the secondary metering jets with PN 4293720. 2. Relieve the tension on the secondary air valve spring by one turn clockwise (both 318 and 360). 3. Adjust the secondary air valve opening to 1/2" (both 318 and 360). 4. Reset basic timing from 4~ to 8~ BTD on 360-4V and from 8~ to 12~ BTD on 318-4V. 5. Reset idle and propane speeds to sea level specifications at altitude. 6. Refer to 1984 Rear Wheel Drive Truck Service Manual for correct procedures for the above adjustments. 7. Type Vehicle Emission Control Information Update Label, PN 4275084, as shown in Figure 1 and install next to or near the original VECI label. NOTE: VEHICLE SHOULD BE RETURNED TO ITS ORIGINAL CONDITION IF DRIVEN AT LOW ALTITUDE. POLICY: Information only Page 2208 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). Service and Repair Ball Stud: Service and Repair Fig. 17 Using puller to remove tie rod (Typical) Fig. 18 Using puller to remove drag link from steering arm. (Typical) MODELS W/FULL TIME 4WD Removal & Disassembly 1. Remove axle shaft cotter pin and loosen outer axle shaft nut. 2. Raise vehicle, then remove wheel assembly. 3. After removing caliper retainer and anti-rattle spring assembly, slide caliper out and away from rotor. Hang caliper out of the way. Do not allow caliper to hang by hydraulic brake hose. Remove inboard brake pad. 4. Remove outer axle shaft nut and washer and through access hole in rotor assembly; remove the six bearing retainer bolts. 5. Secure a suitable puller to wheel studs and tighten main screw of tool to remove hub, rotor, bearings, retainer and outer seal as an assembly. Remove puller from rotor. 6. Remove brake caliper adapter from knuckle, then remove and discard O-ring from knuckle, if equipped. 7. Carefully pull axle shaft assembly out and remove seal and slinger from shaft. 8. Disconnect tie rod from steering knuckle using a suitable tool, so as not to damage seal. 9. On left side only, disconnect drag link from steering knuckle arm again using a suitable tool to avoid seal damage. 10. Remove nuts from steering knuckle arm on left side only. Tap arm to loosen tapered dowels. Remove dowels and arm. 11. Remove cotter pin from upper ball joint nut then remove upper and lower ball joint nuts. Discard lower nut. 12. Separate steering knuckle from axle housing yoke using a brass drift and a hammer, then, using a suitable tool, remove and discard sleeve from upper ball joint yoke on axle housing. 13. Secure steering knuckle uPSIde down in a vise and remove snap ring from lower ball joint. 14. Use proper tools to press upper and lower ball joints from steering knuckle. Replace ball joints if any looseness or endplay exists. Page 3165 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. Page 913 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. Page 2709 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. 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 Removal & Installation Crankshaft Position Sensor: Service and Repair 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. Page 218 Fig. 5 Speed control wiring diagram. 1984 Mini-Vans/Wagons (1985 similar) 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. Page 2267 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). 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. 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. Page 3551 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. Page 1351 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. Page 2247 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. Page 2130 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. Page 1960 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. Page 1479 FIGURE 7 - ELECTRIC FUEL PUMP WIRING DIAGRAM Page 1433 Crankshaft Position Sensor: Service and Repair 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. Page 3658 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 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. Diagram Information and Instructions Trailer Lighting 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. 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. Page 2625 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. Page 3844 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 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. Page 682 Fuse: Service and Repair Circuit Breaker/Fuse Replacement Door Lock And Power Window Circuit Breaker And Relays Location Disconnect the battery negative terminal. Remove the two wires from the circuit breaker and remove the circuit breaker from its mounting clip. Install new circuit breaker to the mounting clip and connect the two wires. Connect the battery negative terminal and test power door lock system for proper operation. Locations Choke Temperature Control Switch: Locations Upper RH Side Of Engine Page 1458 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 Page 3902 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. 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 Auto Locking Hubs - Not Locking/Unlocking Wheel Hub (Locking): Customer Interest Auto Locking Hubs - Not Locking/Unlocking Models 1981-1984 "W" Model Trucks Equipped With Automatic Locking Hubs Subject Automatic Locking Hubs Will Not Operate During Low Temperatures Index FRONT SUSPENSION Date October 28, 1985 No. 02-10-85 SYMPTOM/CONDITION Customer concern of automatic locking hubs not locking/unlocking during below freezing weather. DIAGNOSIS Road test the vehicle and check for hubs locking/unlocking. NOTE: IF AMBIENT TEMPERATURES ARE ABOVE FREEZING, THE HUBS MAY OPERATE PROPERLY, THEN VISUAL INSPECTION IS REQUIRED. REMOVE THE COVER FROM THE HUB. INSPECT THE HUB FOR THE PRESENCE OF WATER CONTAMINATION. THIS WILL APPEAR IN THE FORM OF DISCOLORED GREASE OR RUST. If the hub is water contaminated, perform the following operation: PARTS REQUIRED Hub Repair Package PN 4411998 (as required) REPAIR PROCEDURE 1. Remove hub from axle. 2. Inspect the hub carefully to determine the extent of the water damage. If the hub components are corroded beyond repair, replace the hub assembly with new hub, PN 4384120. If damage to the hub is light, do the following: 3. Disassemble the hub and clean thoroughly to remove all contaminants Refer to Rear Wheel Drive Truck Service Manual for service procedure. 4. Inspect all components, especially the drag sleeve, brake band, and inner and outer cages for damage. Replace as necessary. 5. Reassemble the hub. 6. Lubricate the hub by dipping all components except the bearing and race assembly, brake band, and drag sleeve assembly in automatic transmission fluid. 7. Allow the excess transmission fluid to drip off. 8. Repack the bearing and race assembly with Darmex Lubricant, PN 4293040. 9. Lubricate the brake band and drag sleeve with Darmex Lubricant, PN 4293040. IMPORTANT: DO NOT SUBSTITUTE ANY OTHER LUBRICANT FOR THE DARMEX LUBRICANT SPECIFIED IN STEPS 8 AND 9, OR FAILURE OF THE HUB TO OPERATE PROPERLY COULD RESULT. 10. Reassemble and install the hub as outlined in the service manual. Page 2862 4. Be sure reservoir is seated. The bottom of the reservoir should touch the top of the grommet. Specifications Page 387 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Mounted Switches & Sensors. Upper LH Side Of Engine Page 1633 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. Page 272 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 Page 2689 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. Page 1680 FIGURE 3D - BODY WIRING Page 2869 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. 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. Page 1605 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. Page 530 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. Page 3166 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. Page 333 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. 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 Page 3052 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. Page 1893 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 Page 1543 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. Diagram Information and Instructions Intake Air Temperature 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. Page 3744 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. Page 271 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 Page 2158 FIGURE 3C - BODY WIRING Page 2942 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 Specifications Brake Caliper: Specifications Adapter Mounting Bolts 150 ft.lb Retainer And Anti-rattle Spring 200 in.lb Locations Oil Pressure Sender: Locations Engine Mounted Switches & Sensors. Top Of Engine Applicable to: V8 Engine Page 3254 11. Install new cover and screws with "O" rings, PN 4411998. 12. Torque the cover screws to 40-50 inch pounds (4.5 - 5.6 N-m). 13. Check the hubs for locking/unlocking. POLICY: Information only Page 543 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 Page 48 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 Specifications 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. Page 2024 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 Page 1188 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. 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 Page 2152 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 Page 2342 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* Page 2189 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. 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. Page 1987 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 Page 3866 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. Page 2173 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 Page 1691 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 Page 1272 Manifold Pressure/Vacuum Sensor: Locations Combustion Control Computer Location. Upper RH Side Of Engine Applicable to: 1981-84 Page 3921 Fig. 11 Clearance & Identification Lamps Sweptline Box Wiring Circuits. 1983-84 W/Dual Rear Wheels Page 3629 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 Page 3504 Fig. 5 Speed control wiring diagram. 1984 Mini-Vans/Wagons (1985 similar) Page 1620 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). Page 1736 Manifold Pressure/Vacuum Sensor: Locations Combustion Control Computer Location. Upper RH Side Of Engine Applicable to: 1981-84 Page 658 Engine Oil: Specifications TYPE.................................................................................................................................................... .............................................SF, SF/CC, SG, SG/CD CAPACITY, Refill: All models........................... .............................................................................................................................................................. .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 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. Page 2101 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. Page 1599 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. Removal & Installation Crankshaft Position Sensor: Service and Repair 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. Page 2268 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. Page 252 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). Page 117 FIGURE 3C - BODY WIRING Page 2204 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 Locations Intake Air Temperature Switch: Locations Engine Mounted Switches & Sensors. Upper RH Side Of Engine Page 1690 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. Page 687 Fig. 1 Fuse Panel. 1983-84 Page 112 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. Page 334 FIGURE 3D - BODY WIRING Page 3145 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. Page 536 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. 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 Page 294 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. 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. Page 41 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. Page 1151 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. Page 2449 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. Page 292 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. Page 78 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 Page 1233 Ignition Control Module: Mechanical Specifications Part No. Spark Advance Test Electronic EGR Time Delay Electronic Throttle Control 4289075 44 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289077 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289086 44 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289094 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. 4289304 39 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289308 43 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289310 42 +/- 4 deg at 2000 rpm 20 min 20 sec 4289324 20 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289326 21 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289351 39 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289352 43 +/- 4 deg at 2000 rpm 60 min 60 sec Note: After start or 2 sec. after throttle close position. 4289356 20 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289357 21 +/- 4 deg at 2000 rpm 65 min 65 sec Note: After start or 3 sec. after throttle close condition. 4289364 42 +/- 4 deg at 2000 rpm 20 min 20 sec Note: After start or 1 sec. after throttle close condition. Locations Air Injection Pump: Locations Front Of Engine Applicable to: 1984-85 V8 Engine Page 3342 Trailer Lighting Module: Electrical Diagrams Fig. 45 Trailer Tow & Camper Wiring Circuit (Part 1 of 2). 1983-84 Fig. 45 Trailer Tow & Camper Wiring Circuit (Part 2 of 2). 1983-84 Page 672 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. Page 1446 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) Page 2225 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 Page 282 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). Page 3663 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 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. Page 3447 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 Page 3197 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. Page 858 Engine Oil: Specifications TYPE.................................................................................................................................................... .............................................SF, SF/CC, SG, SG/CD CAPACITY, Refill: All models........................... .............................................................................................................................................................. .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 Page 1899 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 Page 1968 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). Page 3596 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. Page 1961 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) Locations Feedback Control Solenoid: Locations Engine Mounted Switches & Sensors. On Carburetor Applicable to: V8 Engine Page 324 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 Page 3104 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. Page 3117 Fig. 19 Tilt wheel steering column exploded view. Front wheel drive Mini-Vans/Wagons Fig. 20 Lock plate retaining ring removal 1. Remove bracket assembly to column jacket attaching bolts. 2. Remove wiring protector from column jacket. 3. Attach holding fixture C-4132 or equivalent to column, then mount column in a vise by clamping at holding fixture. 4. Remove tilt lever and turn signal or speed control lever. 5. Push hazard warning knob and remove by unscrewing, then remove ignition key lamp, if used. 6. If not removed previously, remove steering wheel using a suitable puller. Do not attempt to remove steering wheel using a hammer, as damage to steering column and shaft will result. 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. Page 596 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. Page 3880 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. 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) Page 3855 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).