Dodge RAM 1997 Workshop Manual

dodge :: Dodge Truck D50/Ram 50 L4-1997cc 2.0L

SOHC (1984)

> Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations

Headlamp Relay: Locations

Left Side Front Fender Shield

Applicable to: 1981-84

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >

Locations

Powertrain Control Module: Locations

Under LH Side Of I/P

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Throttle Control Vacuum Motor <--> [Engine Speed Governor Control Module] > Component

Information > Locations

Throttle Control Vacuum Motor: Locations

Under Center Of I/P

> Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations

Starter Relay: Locations

Inner Left Side Of Wheelwell


> Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations

Wiper Relay: Locations

Left Side Of Fender Shield


> Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications

Coolant Temperature Sensor/Switch (For Computer): SpecificationsSwitch Torque

Switch Torque

Cooling Fan Switch 8-18 ft.lb

> Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations

Clutch Switch: Locations


> Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair

Brake Light Switch: Service and Repair

Adjusting Stoplamp Switch Clearance

The stop light switch also serves as a brake pedal stopper and is located under the instrument panel, behind the brake pedal. Disconnect the wire, thenremove retaining nut from bracket and the switch. Reverse procedure to install. Ensure brake pedal height is correct, then adjust switch to obtain aclearance of .02 to .04 inch between switch housing and pedal stopper with pedal released.

> Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Service and Repair

Headlight Switch: Service and Repair

On models equipped with dash mounted light switch, the switch is serviced with the instrument cluster. Refer to `Ìnstrument Cluster, Replace''procedure. On models equipped with turn signal mounted light switch, the switch is serviced with the turn signal/combination switch. Refer to ``VehicleLighting/Turn Signals/Turn Signal Switch/Service and Repair'' for procedure.

> Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair

Turn Signal Switch: Service and Repair

1. Disconnect battery ground cable.2. Remove steering wheel using a suitable puller. Scribe alignment mark between steering wheel and shaft to ensure proper installation. On models with tilt steering columns, place column in lowest position during steering wheel removal.

3. Remove upper and lower steering column covers.4. Remove wiring harness retaining straps, if equipped, then disconnect electrical connectors.5. Remove column switch assembly.6. Reverse procedure to install, noting the following: a. Ensure column switch is properly aligned with steering shaft center.b. Attach switch wiring along column tube as close to center line as possible.c. Retain wiring using suitable retaining straps to prevent contact with other parts.

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >

Specifications


Switch Torque


> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair

Ignition Switch: Service and Repair

The ignition switch is mounted in the rear of the steering column lock. When the key is turned to LOCK position and pulled out, the lock pinautomatically ejects from the cylinder and enters a groove in the steering shaft, locking the steering wheel. The heads of the bolts securing the steering lock assembly shear off when the bolts are tightened. Replacement of the steering lock assembly mayrequire that the steering column be removed, as these bolts must be cut or slotted to permit removal with a screwdriver. When the lock assembly isinstalled, new shear bolts must be used and the bolts should be tightened until the bolt heads twist off. However, the ignition switch can be serviced separately from the lock assembly using the following procedures.

1.

Disconnect battery ground cable, then remove upper and lower column covers.

2.

Remove bands securing switch harness and disconnect electrical connector.

Fig. 4 Ignition switch removal

3.

Loosen the bolt holding the switch and pull from lock assembly.

4.

Reverse procedure to install, first inserting key to check for proper operation.

> Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations



> Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Service and Repair



1.


2.



3.


4.


> Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair

Neutral Safety Switch: Service and Repair

1.

Loosen shift lever handle setscrew, then remove shift lever handle.

2.

Remove shift position indicator attaching screws, then the position indicator by lifting upward.

3.

Disconnect shift position indicator light from indicator assembly, then the neutral safety switch wiring.

4.

Loosen neutral safety switch adjustment screws, then remove attaching screws and switch.

5.

Reverse procedures to install, noting the following:

Fig. 8 Positioning selector lever for neutral safety switch installation. Ram Raider & 1984-86 Ram 50 a. Position selector lever as shown, install switch on selector lever bracket leaving screws loose, then connect suitable ohmmeter to switch terminals.

Fig. 9 Neutral safety switch clearance. Ram Raider & 1984-86 Ram 50 b. Move switch forward and backward through range of adjustment noting meter indication, and scribe alignment mark between switch and

are aligned, then tighten switch mounting screws.

> Maintenance > Alignment > System Information > Technical Service Bulletins > Alignment - Caster Adjustment Manual Revision

Alignment: Technical Service BulletinsAlignment - Caster Adjustment Manual Revision

Models

All Ram 50 Two & Four Wheel Drive Vehicles

Subject

Caster Adjustment - Service Manual Revision

Index

FRONT SUSPENSION

Date

03/18/85

No..

02-07-85

P-887C

Caster Adjustment

This bulletin is issued to supplement the service manual information regarding caster adjustment for Ram 50 pick-up trucks.

Caster

Two Wheel Drive

Four Wheel Drive

Specifications

2-1/2~ +/- 1~

2~ +/- 1~

NOTE:

POLICY:

CASTER DIFFERENCE BETWEEN LEFT HAND AND RIGHT HAND SIDES SHOULD NOT EXCEED 1/2~.

Information only

> Maintenance > Alignment > System Information > Technical Service Bulletins > Page 68

Alignment: Specifications

Caster Angle

4WD

+1 to +3 deg

Except 4WD

+1 1/2 to +3 1/2 deg

Desired Caster

Camber Angle

2 deg 2 1/2 deg

Front +1/2 to +1 1/2 deg +1/2 to +1 1/2 deg

1 deg

Desired Camber Angle Front ---

Rear 1 deg

---

Toe

Rear

Front .08-.35 in

Rear ---

---

.08 to .35 in

---

> Maintenance > Alignment > System Information > Service and Repair > Camber

Alignment: Service and RepairCamber

FRONT

WITH TWO WHEEL DRIVE

1. Using tool No. MB990805 to hold upper arm shaft to crossmember bolt in position, remove nut from engine compartment side and adjust the number of shims between upper arm shaft and crossmember.

2. The normal shim pack thickness is 0.16 inch. A change of 0.024 inch in thickness of the shim pack will provide a change of approximately 2/15 degree in camber adjustment.

WITH FOUR WHEEL DRIVE

Adjust number of shims between upper arm shaft and arm post of side frame. The normal shim package thickness is 0.12 inch. A change of 0.039 inchin thickness of shim pack will provide a change of approximately 13 minutes in camber adjustment. Camber adjusting shims are available inthicknesses of 0.039 and 0.079 inch.

REAR

Rear camber is pre-set during vehicle assembly and cannot be adjusted. If camber is not within specifications, check for worn or damaged suspensioncomponent, and damaged or deformed floor pan or body and repair as needed.

> Maintenance > Alignment > System Information > Service and Repair > Camber > Page 71

Alignment: Service and RepairCaster

Fig. 2 Caster adjustment. Ram Raider & 1984-86 Ram 50

Caster is adjusted by turning the upper control arm shaft as follows:1. Remove upper control arm.2. Rotate upper control arm shaft to alter caster setting. One half turn of the upper control arm shaft will cause the upper arm shaft to move approximately 0.049 inch forward or rearward, resulting in approximately 17 minute (17/60) change in caster setting.

3. Reinstall control arm and recheck caster.4. Repeat adjustment until caster is within specifications. Maximum variation between left and right sides should be less than 1/2.


Alignment: Service and RepairPreliminary Inspection

1. Road test vehicle noting any abnormal steering or handling characteristics.2. Ensure tires are the proper type, correctly inflated and that tires on each axle are the same size.3. Inspect ball joints, suspension arms, bushings and tie rods, and repair or replace any component that is damaged or excessively worn.4. Ensure wheel runout is not excessive, and that wheel bearings are properly adjusted.5. Jounce vehicle several times to settle suspension.6. Place vehicle on suitable alignment rack following manufacturer's instructions. On Ram 50 and Ram Raider models, remove hub cap and cotter pin

(2WD) or free wheeling hub (4WD), and attach alignment gauges to wheel hub.

7. Check and correct alignment angles in the following sequence: Rear toe and camber, caster, front camber and front toe.8. Correct any angle that is not within specifications. If no adjustment is possible, check for damaged or worn suspension components and/or damaged or distorted chassis and correct as needed.


Alignment: Service and RepairToe Adjustment

FRONT

On Colt models, remove outer bellows clip from tie rod before adjusting toe. After completing adjustment, reinstall clamp.The amount of toe-in of the left front wheel is reduced by turning the tie rod turnbuckle toward the front of the car and the amount of toe-in on theright front wheel is reduced by turning it toward the rear of the the car. After adjustment, the difference in length between the two tie rods should notexceed 0.2 inch (5 mm).

REAR

Rear toe is pre-set during vehicle assembly and cannot be adjusted. If toe is not within specifications, check for worn or damaged suspensioncomponents, and damaged or deformed floor pan or body and repair as needed.

> Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications

> Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > By Symptom for Air/Fuel Mixture: > 140884 > Jan > 84 > Propane Idle Set - Procedure

Air/Fuel Mixture: By SymptomPropane Idle Set - Procedure

Models

1984 MMC Import Vehicles All With Gasoline Fueled Engines, All Emission Markets (Except Vehicles With Turbo Chargers & Canada)

Subject

Propane Idle Set Procedure

Index

FUEL

Date

January 17, 1984

No..

14-08-84

P-94-C

The propane idle set procedure is authorized for 1984 subject model import vehicles.

The propane idle set method is to be used when "CO" meter procedure cannot be used, i.e., "CO" meter in for repair or is not available in the servicearea.

PROPANE IDLE CHECK & SET PROCEDURE

1.

Idle Setting Conditions: Lights, electric cooling fan, and all accessories are off, transmission in neutral, and front wheels in straight ahead position.

2.

If engine is cold, allow it to warm up until full operating temperature is reached (185 to 205~F).

NOTE:

PERFORM THE FOLLOWING STEPS 3 THROUGH 5 AND STEP 19 ONLY IF ENGINE IS EQUIPPED WITH A FEEDBACKCARBURETOR EMISSION SYSTEM.

3.

Turn off ignition switch.

4.

Disconnect the NEGATIVE cable from the battery for about 5 seconds. Then reconnect negative battery cable.

5.

Disconnect the connector of the exhaust oxygen sensor.

6.

Start and run engine for 5 seconds at an engine speed between 2,000 to 3,000 rpm.

7.

Then, allow engine to run at curb idle for 2 minutes.

> Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > By Symptom for Air/Fuel Mixture: >

140884 > Jan > 84 > Propane Idle Set - Procedure > Page 86

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

8.

Check engine idle speed and basic ignition timing. Adjust to specifications if necessary (Figure 1).

9.

Disconnect the air cleaner fresh air intake duct from the air cleaner snorkel.

Insert the propane supply hose into the air cleaner snorkel about 4 inches.

Make certain both valves on propane bottle are fully closed and the bottle is upright and in a safe location.



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 3

10.

Open the propane bottle main valve fully, then slowly open the propane fine control valve to the position where maximum engine rpm is achieved.(Too much propane or too rich idle mixture will cause the engine to lose rpm as the fine control valve is opened.) (Figure 3.)

FIGURE 2



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

Note the engine rpm increase. Specified values of each engine propane idle speed increase are outlined in Figure 2.

If the propane idle speed exceeds more than 25 rpm from the specified value in Figure 2 or the rpm does not increase at all, idle fuel mixtureshould be adjusted according to the propane assisted idle set procedure that follows.

FIGURE 4

11.

It is not necessary to remove carburetor from intake manifold to remove the idle mixture screw plug.

Drill out concealment plug on car. Remove vacuum connector from high altitude compensator (HAC) fittings on carburetor air horn (Figure 4).

Use a 1/4" diameter drill 8' long at the 11 o'clock position on the plug boss. Locate drill point 3/16" from end of boss.

Plug should pop out when the drill bit contacts it (Figure 4).

12.

Start engine and run for 1 minute at engine speed of 2500 rpm.

13.

Run engine at idle for 2 minutes.



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

14.

Open the propane main valve and slowly open the fine control valve to the position where maximum engine speed is achieved. Use the idle speedadjusting screw to set the specified propane idle speed from Figure 2.

15.

Turn off propane main valve and adjust idle mixture screw to the specified idle set speed from Figure 2.

16.

17.

To recheck the maximum propane speed, open the main propane valve again. If the speed still differs more than 25 rpm from the specified propanespeed from Figure 2, repeat Steps 14 through 16.

18.

Remove the propane hose and replace fresh air duct on air cleaner snorkel.

19.

Reconnect the exhaust oxygen sensor (if engine is equipped with a feedback carburetor).

20.

Install Idle Mixture Screw Concealment Plug. (If new plug is needed, use PN MD606954.)

POLICY: Reimbursable within the provisions of the warranty



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FRONT WHEEL DRIVE LABOR OPERATION TIME SCHEDULE

FAILURE CODE: RO - Driveability

> Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > All Technical Service Bulletins for Air/Fuel Mixture: > 140884 > Jan > 84 > Propane Idle Set

- Procedure

Air/Fuel Mixture: All Technical Service BulletinsPropane Idle Set - Procedure

Models


Subject


Index

FUEL

Date

January 17, 1984

No..

14-08-84

P-94-C




1.


2.


NOTE:


3.


4.


5.


6.


7.


> Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > All Technical Service Bulletins for Air/

Fuel Mixture: > 140884 > Jan > 84 > Propane Idle Set - Procedure > Page 96

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

8.


9.






D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 3

10.


FIGURE 2



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



FIGURE 4

11.





12.


13.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

14.


15.


16.

17.


18.


19.


20.





D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



> Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > By Symptom: > 140884 > Jan > 84 > Propane Idle Set - Procedure

Idle Speed: By SymptomPropane Idle Set - Procedure

Models


Subject


Index

FUEL

Date

January 17, 1984

No..

14-08-84

P-94-C




1.


2.


NOTE:


3.


4.


5.


6.


7.


> Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > By Symptom: > 140884 > Jan > 84 > Propane

Idle Set - Procedure > Page 109

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

8.


9.






D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 3

10.


FIGURE 2



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



FIGURE 4

11.





12.


13.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

14.


15.


16.

17.


18.


19.


20.





D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



> Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 142084 > May > 84 > Engine Specifications -

Manual Corrections

Idle Speed: All Technical Service BulletinsEngine Specifications - Manual Corrections

Models

1984 Colt, Ram 50, & Conquest

Subject

Correction of 1984 Service Manuals on Engine Specifications

Index

FUEL

Date

May 21, 1984

No..

14-20-84

P-2112-C

This service bulletin is issued to correct the following 1984 Import Service Manuals.

^ Colt Service Manual Publication #81-270-4006

> Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed:

> 142084 > May > 84 > Engine Specifications - Manual Corrections > Page 119

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

^ Ram-50 Service Manual Publication #81-370-4009

^ Conquest Service Manual Publication #81-270-4005

Corrections are highlighted in the attached specifications in bold type and should be entered in the respective model service manual.

POLICY: Information only

> Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 141984 > May > 84 > Carburetor - Idle Speed

Adjustment on A/C Install

Idle Speed: All Technical Service BulletinsCarburetor - Idle Speed Adjustment on A/C Install

Models

1984 Colt (W/O Turbo), Ram-50, Power Ram-50 (W/O Diesel) & Colt Vista

Subject

Idle-Up Speed Adjustment After Air Conditioning Installation and/or Service

Index

FUEL

Date

May 7, 1984

No.

14-19-84

P-1927-CThis procedure modifies the adjustment procedures in the subject model service manuals.

If difficulty is encountered in adjusting curb idle speed and/or idle-up speed after installation or servicing and adjustment of the air conditioning system,follow the adjustment procedure as outlined below:

ADJUSTMENT PROCEDURE

1.

Thoroughly warm up engine, turn off all accessories, front wheels in straight ahead position, transmission in neutral, parking brake set, andradiator cooling fan stopped.

FIGURE 1


> 141984 > May > 84 > Carburetor - Idle Speed Adjustment on A/C Install > Page 124

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

2.

Check and adjust curb idle speed if necessary (see Figure 1 for specification) and make adjustment using SAS (speed adjusting screw) 1 (Figure2). On some models installation of air conditioner will change the curb idle speed already adjusted.

FIGURE 2

3.

Back off the idle-up speed adjusting screw for air conditioner one turn from fully tightened position (Figure 2).

4.

Lift the free lever by hand until it touches SAS 3 and record the engine speed ("N" = R.P.M.) obtained at this time (Figure 2).



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

FIGURE 2

5.. Turn on air conditioner switch. Adjust the idle-up speed while compressor is running to the specified rpm (Figure 1) by turning SAS 2 (Figure 2).When making this adjustment, be sure to record the turning direction and slot angle of SAS 2.

FIGURE 1

6.

Turn off air conditioner switch and make sure that the specified curb idle rpm is obtained (Figure 1).

7.

Race the engine at a speed of about 2000 rpm for five seconds.

8.

Turn on and then off the air conditioning switch repeatedly several times and make sure that with the compressor running that the engine is running



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

at the specified idle-up rpm (Figure 1).

Example:

FIGURE 2

If Sas 2 has been turned 180~ clockwise in Step 5, SAS 3 will be turned 360~ clockwise in Step 9. Then, lift thefree lever by hand until it touches SAS 3 and make sure that the engine rpm is "N" +/- 100 rpm (where "N" is therpm recorded in Step 4). If necessary, adjust using SAS 3.

FIGURE 2

SIMPLE ADJUSTMENT PROCEDURE FOR COLT VISTA ONLY

If the idle adjustment has been properly made before installation of the air conditioner, the following simple procedure may be used:

1.

Give one clockwise turn to SAS 2 (Figure 2).

2.

Give two clockwise turns to SAS 3 (Figure 2).

3.

Back off idle-up speed adjusting screw for air conditioner one turn from fully tightened position (Figure 2).



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

4.

Lastly, make sure that the curb idle speed and idle-up speed are properly adjusted (Figure 1).

FIGURE 2

If necessary, make fine adjustments with SAS 2 and SAS 3 (Figure 2).


FAILURE CODE: 31 - Rough Idle

> Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 140884 > Jan > 84 > Propane Idle Set - Procedure

Idle Speed: All Technical Service BulletinsPropane Idle Set - Procedure

Models


Subject


Index

FUEL

Date

January 17, 1984

No..

14-08-84

P-94-C




1.


2.


NOTE:


3.


4.


5.


6.


7.



> 140884 > Jan > 84 > Propane Idle Set - Procedure > Page 132

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

8.


9.






D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 3

10.


FIGURE 2



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



FIGURE 4

11.





12.


13.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

14.


15.


16.

17.


18.


19.


20.





D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



> Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > 142084 > May > 84 > Engine Specifications - Manual

Corrections


Models


Subject


Index

FUEL

Date

May 21, 1984

No..

14-20-84

P-2112-C



> Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: >

142084 > May > 84 > Engine Specifications - Manual Corrections > Page 142

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)





> Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > 141984 > May > 84 > Carburetor - Idle Speed



Models


Subject


Index

FUEL

Date

May 7, 1984

No.

14-19-84




1.


FIGURE 1


141984 > May > 84 > Carburetor - Idle Speed Adjustment on A/C Install > Page 147

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

2.


FIGURE 2

3.


4.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

FIGURE 2


FIGURE 1

6.


7.


8.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)


Example:

FIGURE 2


FIGURE 2



1.


2.


3.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

4.


FIGURE 2




> Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 151

> Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications

FIRING ORDER 2.0L RWD & 2.6L

> Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams

Timing Marks and Indicators: Diagrams

TIMING MARK 1.6L RWD, 2.6L & 2.0L EX. VISTA

> Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams > Page 159

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

TIMING MARK 1981-85 5.2L & 5.9L

> Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Vacuum Advance Unit <--> [Distributor Advance Unit] > Component Information > Specifications > Electrical Specifications

Vacuum Advance Unit: Electrical Specifications

> Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Vacuum Advance Unit <--> [Distributor Advance Unit] > Component Information > Specifications > Electrical Specifications > Page 165

> Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 181788 > Oct > 88 > Spark Plugs - Oil Fouling/Misfire on

Hard Acceleration

Spark Plug: Customer InterestSpark Plugs - Oil Fouling/Misfire on Hard Acceleration

Models

1978-1989 MMC Engines With Jet Valves

Subject

Oil Fouled Spark Plug(s) Miss & Bucking Under Hard Acceleration

Index

FUEL

Date

October 17, 1988

No.

18-17-88

C18-21)This bulletin updates Technical Service Bulletin 5/14/88 and serves as a reminder that driveability problems may be caused by mechanical problems aswell as fuel system problems.

FIGURE 1

SYMPTOM/CONDITION

One or more (seldom occurs to more than one cylinder) spark plugs will be oil fouled and may show ground and center electrode erosion due tooverheating (Figure 1).

Under hard acceleration (wide open throttle) engine will miss and buck.

> Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: >

181788 > Oct > 88 > Spark Plugs - Oil Fouling/Misfire on Hard Acceleration > Page 174

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

This condition may result from a jet valve failure. The jet valve failure is characterized by one of the causes outlined below (refer to Figure 2 fordescription):

^ Oil leaking past the oil seal and valve stem.

^ Oil leaking past the valve body and oil seal.

^ Oil leaking past the O-ring seal between the valve body and cylinder head which may be caused by a torn or cut Oring.

FIGURE 1

DIAGNOSIS

Remove and inspect all spark plugs. If a spark plug is found to be heavily oil fouled and/or appears to have the electrodes eroded or overheated, proceedto jet valve removal procedure below (Figure 1).PARTS REQUIRED

Jet Valve Assembly (as required)

O-Ring (as required)

INSTALLATION PROCEDURE

PN MD009440

PN MD009786

1.

Remove only the jet valve of the cylinder showing the spark plug oiling or overheating. Follow the jet valve removal procedures outlined in therespective model year service manual using Miller Special Tool #MB-998310.



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

2.

Push jet valve open and inspect the valve stem just under the valve head. If oil residue and excessive carbon buildup are present, the Jet ValveAssembly, PN MD009440, will have to be replaced (Figure 2).

If no residue or carbon buildup is present, inspect the O-ring for rips, tears, or deformity. O-ring can be replaced separately with PN MD009786.

FIGURE 3

3.

Inspect jet piece pocket by looking down into jet piece. If pocket has any buildup of burnt oil residue or carbon, it must be cleaned completelyusing the following procedure (Figure 3).

a.

Remove spark plug.

b.

Place piston on top dead center of compression stroke (both valves closed).

Use a thin stiff bristle brush to clean jet piece (a distributor cap terminal brush works well). A thin metal rod (coat hanger) can be used toloosen heavy deposits.

d.

Direct compressed air in jet piece. The loosened deposits will be blown out of the jet piece and spark plug hole. Eye protection isrecommended when performing this operation.

e.

Reinspect cleaned jet piece. If cracking or erosion is seen in the area of the jet air orifice (Figure 3) or the deposit cannot be cleanedadequately, the cylinder head will require replacement.



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

4.

Install new spark plug of proper heat range and gap setting.

5.

Start engine and allow to fully warm up. Check for oil leaks and adjust idle speed if necessary.


> Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 181788 > Oct > 88 > Spark Plugs - Oil

Fouling/Misfire on Hard Acceleration

Spark Plug: All Technical Service BulletinsSpark Plugs - Oil Fouling/Misfire on Hard Acceleration

Models


Subject


Index

FUEL

Date

October 17, 1988

No.

18-17-88


FIGURE 1

SYMPTOM/CONDITION



> Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark

Plug: > 181788 > Oct > 88 > Spark Plugs - Oil Fouling/Misfire on Hard Acceleration > Page 182

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2





FIGURE 1

DIAGNOSIS





PN MD009440

PN MD009786

1.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

2.



FIGURE 3

3.


a.

Remove spark plug.

b.



d.


e.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

4.


5.



> Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 185

> Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications

Compression Check: Specifications

Pressure 170 psi

> Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications

Valve Clearance: Specifications

Except Jet Valve Intake 0.006 in

1985-89 2.0L & 2.6L except jet valve have hydraulic lifters.

Jet Valve

Exhaust 0.01 in

Intake 0.006 in

> Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 192

Valve Clearance: Adjustments

INTAKE & EXHAUST VALVES

Fig. 12 Adjusting valve clearance (Typical)

The jet valve must be adjusted before adjusting the intake valve.

1. With engine at operating temperature, remove rocker arm cover.2. Disconnect high tension lead from ignition coil.3. While observing rocker arms on No. 4 cylinder, rotate crankshaft until the exhaust valve is closing and the intake valve has just started to open

Fig. 12.

with crankshaft pulley mark aligned with TDC mark on timing chain case. At this position the No. 1 cylinder is at top dead center compressionstroke. Check and adjust valve clearance for both intake and exhaust valves of No. 1 cylinder, intake valve of No. 2 cylinder and exhaust valve ofNo. 3 cylinder, as necessary,

4. Rotate crankshaft 360 degrees and check and adjust valve clearance for exhaust valve of No. 2 cylinder, intake valve of No. 3 cylinder and intake and exhaust valves of No. 4 cylinder.

5. After completing adjustment, install rocker arm cover and connect ignition coil high tension lead.

JET VALVE

Fig. 13 Adjusting jet valve clearance

Exc. Models Equipped W/Hydraulic Lash Adjusters

Fig. 13.

Following procedure for intake and exhaust valve adjustment, position No. 1 cylinder at top dead center compression stroke. Loosen intake valveadjusting screw at least 2 turns, then loosen jet valve adjusting screw locknut. Rotate jet valve adjusting screw counterclockwise and insert a suitablefeeler gauge blade as specified in ``Valve Specification Chart,'' between jet valve stem and adjusting screw, Tighten jet valve adjusting screwuntil it contacts the feeler gauge blade, then while holding adjusting screw in position, tighten locknut. After jet valve adjustment has been completed,adjust intake valve clearance. Continue to follow intake and exhaust valve adjustment procedure and adjust jet valves as necessary.

> Maintenance > Timing Belt > Component Information > Adjustments

Timing Belt: Adjustments

1. Remove timing belt front upper cover.2. Carefully check the timing belt on its whole circumference for cracks and peeling.3. Turn crankshaft in normal direction (clockwise) until timing mark on camshaft sprocket is aligned with mating mark on cylinder head, so that piston in No. 1 cylinder is placed at top dead center on compression stroke.

CAUTION:

Do not turn crankshaft in opposite direction (counterclockwise) to align the timing mark with mating mark, otherwise an improper timing belt tension could result.

Timing Marks

4. Turn crankshaft in normal direction (clockwise) until second tooth past timing mark (punch) position on camshaft sprocket should be aligned with timing mark on cylinder head.

Access Cover Location

Removing Access Cover

5. Remove two access covers. Access cover can be easily removed by inserting screwdriver into groove from direction of embossed arrow and pry.6. Insert wrench through adjusting hole and loosen timing belt tensioner tightening bolt and nut.

CAUTION: 180 to 200 Loosen bolt and nut . If they are loosened more than necessary, they might fall into cover.

7. Insert plain screwdriver from top of timing belt cover. Slightly push tensioner bracket in tensioning direction, and then release. Now belt tension

> Maintenance > Timing Belt > Component Information > Adjustments > Page 196

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

will be automatically adjusted by tensile strength of tensioner spring.

CAUTION:

The purpose of pushing tensioner with screwdriver is to loosen tensioner mounting surface which might have stuck due to manyhours of being tightened

8. First tighten tensioner mounting bolt (bottom side) with wrench and then tighten mounting nut (top side).

CAUTION: Make sure that bolt (bottom side) is tightened first. If nut is tightened first, belt tension will vary (will become too tight).

Mounting Access Cover

9. Mount two access covers to respective adjusting holes. Access cover can be easily mounted by sliding in such a way that hook will pass between guide projections.

10. Install timing belt front upper cover.


Timing Belt: Service and Repair

Timing Belt Train

REMOVAL

Remove the parts in numerical order shown, paying attention to the following items.1. Place piston of No. 1 cylinder at top dead center of compression stroke.


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

Securing Tensioner Temporarily

2. Move tensioner fully toward water pump and temporarily secure it.3. If timing belt is to be reused, make an arrow mark which indicates turning direction to ensure that belt is reinstalled in same direction as before.

Preventing Rotation Of Left Silent Shaft

4. When oil pump sprocket nut is removed, first remove plug at left side of cylinder block and insert a screwdriver to keep left silent shaft in position.

8 mm (.3 in.) 60 mm (2.36 in) Screwdriver used for this purpose should have a shaft thick which can be inserted more than .

Removing Timing Belt B

5. Loosen right silent shaft sprocket mounting bolt unit it can be loosened by hand.6. Next, remove tensioner "B" and remove timing belt "B".

CAUTION: After timing belt "B" has been removed, do not attempt loosening bolt, while holding sprocket with pliers, etc.

INSPECTION

1. Check belt in detail if following flaws are evident, replace belt with a new one.

Checking Timing Belt a. Hardened back surface rubber back surface glossy. Nonelastic and so hard that even if a finger nail is forced into it, no mark is produced.


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

Checking Timing Belt b. Cracked back surface rubberc. Cracked or exfoliated canvasd. Cracked tooth bottome. Side of belt crackedf.

g. Side of belt badly worn

NOTE: Normal belt should have clear-cut sides as if cut with a sharp knife.

h. Badly worn teeth

Initial stage: Canvas on load side tooth flank worn (fluffy canvas fibers, rubber gone and color changed to white, and unclear canvas texture).Last stage: Canvas on load side tooth flank worn down and rubber exposed (tooth width reduced).

i. Missing tooth.

INSTALLATION

1. Install crankshaft sprocket, flange and spacer as shown, while paying attention to their mounting directions.

CAUTION: Pay special attention to direction of flange. If it is installed in wrong direction, a broken belt could result.

2. Temporarily secure tensioner at a position closest to water pump.3. install end A of spring to predetermined position on tensioner bracket.4. Install end B of spring to predetermined position on water pump.5. When spacer is installed to right silent shaft, direct spacer with its chamfered end toward shaft for protection of oil seal.

BELT INSTALLATION PROCEDURE

Aligning Timing Marks

1. Align timing mark on each sprocket with corresponding timing mark on front case.2. When timing belt "B" is installed, make certain that tension side has no slack.


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

Installing Tensioner "B"

3. install tensioner "B" with center of pulley located on left side of mounting bolt and with pulley flange directed toward front of engine.

Adjusting Belt Tension

4. Lift tensioner "B" with finger tip to tighten timing belt "B" so that its tension side will be taut. in this condition tighten bolt to secure tensioner

"B". When bolt is tightened, use care to prevent shaft from turning together. If shaft is turned together, belt will be overtensioned.

specification.

Belt deflection 5 to 7 mm (.2 to .3 in.) ..................................................................................................................................................................................

7. Move tensioner fully toward water pump and temporarily secure tensioner.

5. Check to ensure that timing marks are in alignment.6. Check to ensure that when center of span on tension side is depressed with index finger in direction of arrow, deflection of belt is up to

Mounting Timing Belt


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

8. Align timing mark on camshaft sprocket with that on cylinder head.9. Align timing mark on crankshaft sprocket with that on front case.

10. Align timing mark on oil pump sprocket with that on front case.


11. When timing mark on oil pump pulley is aligned with that on front case, be sure to remove plug on left side of cylinder block and insert a screw

8 mm (.3 in.) in 60 mm (2.36 in.)

25 mm(1 in.)

60 mm (2.36in.) driver having shaft diameter. If it can be inserted or more, alignment is correct. If it can be inserted only , turn oil pump sprocket through a turn and realign timing marks. Check to ensure that screwdriver can be inserted more than . Keep screw driver inserted until installation of timing belt is finished.

12. Install timing belt. While making sure that tension side of belt is not slackened, install timing belt onto crankshaft sprocket, oil pump sprocket and camshaft sprocket in that order.

13. Loosen tensioner mounting bolt and nut. By so doing, tensioner will be moved by spring and will apply tension to belt.14. Check that portion of belt which is indicated by arrow A to make sure that it is not floating up.15. Tighten tensioner mounting nut and bolt. Tighten slot side bolt before tightening fulcrum side nut. If fulcrum side nut is tightened earlier, tension bracket will be turned together and belt will be overtensioned.

16. Check to ensure that timing marks on all sprockets are in alignment with respective timing marks.17. Turn crankshaft.

CAUTION: Do not turn crankshaft in reverse direction. Crankshaft should be turned smoothly clockwise.

18. Loosen tensioner mounting nut and bolt.19. Tighten tensioner mounting nut and bolt. Be sure to tighten fulcrum side nut and bolt in Step 15.

Adjusting Timing Belt Tension

20. Check to ensure that when center of belt span on tension side and seal line of under cover are held between thumb and forefinger as illustrated, clearance C between belt and seal line is as follows:

Clearance C Approx. 14 mm. (.55 in.) ................................................................................................................................................................................

> Maintenance > Drive Belt > Component Information > Specifications

Drive Belt: Specifications

1981-84 ex. Diesel: One-fourth of a inch or 6-10 millimeter deflection at midpoint of belt between water pump & alternator, under a 22 lb load.

> Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Oil Filter - Addition of Second Supplier

Oil Filter: Technical Service BulletinsOil Filter - Addition of Second Supplier

Models

1984 Colt, Vista, Conquest, D-50 Pick-Up Except With Diesel Engines

Subject

Addition of Second Oil Filter Supplier

Index

ENGINE

Date

December 10, 1984

No.

09-12-84Beginning in July, 1984, MMC began using a second supplier for oil filters in production on all car lines except D-50 pick-up trucks equipped withdiesel engines. The alternate filter is identified by PN

MD084963.

For service parts, use the present replacement filter, PN MD031805, as a replacement for either MD084963 or MD031805.


> Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > Carburetor Coolant Hose - Installation Procedure

Coolant Line/Hose: Technical Service BulletinsCarburetor Coolant Hose - Installation Procedure

Models

All 1984 Import MMC Vehicles With Carburetors Except 2.6L Engines

Subject

Correct Carburetor Coolant Hose Installation Procedure

Index

FUEL

Date

December 3, 1984

No.

14-62-84

P-5298-CThe procedure described in this bulletin should be utilized when servicing the coolant hose or carburetor for the wax pellet choke housing.

FIGURE 1

When installing the lower coolant hose on the wax pellet choke housing, the following steps should be followed to avoid interference of the tab end ofthe hose clamp with the accelerator cable (Figure 1).

1.. Lower coolant hose should only be pushed on up to the shoulder on choke housing nipple (Figure 1).

2.

Tab ends of the spring hose clamps for the lower coolant hose should be positioned downward (Figure 1).


> Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Recycling Recommendations

Coolant: Technical Service BulletinsEngine Coolant - Recycling Recommendations

SUBJECT:

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 systemshave been advertised as producing a recycled antifreeze "as good as" original and suggest the recycled product is suitable for use in Chrysler Corporationvehicles.

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 likenew 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.

> Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Page 220

Coolant: Specifications

1982-89 Ram 50

* 9.0 L (9.5 qts) Cooling System Capacity .............................................................................................................................................................................

* Includes 0.65 L (0.69 qts) for the coolant reserve tank.

> Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Automatic Transmission - New Fluid Type

Fluid - A/T: Technical Service BulletinsAutomatic 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-2131A new automatic transmission fluid Type 7176, (PN 4318077 - quart and 4318079 - 55 gallon) has been released for all vehicles equipped withautomatic 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 shudderand/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 toattempting any other repairs, especially if the fluid has been changed previously.


> Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Transaxle/Transmission - Automatic

Fluid - A/T: SpecificationsTransaxle/Transmission - Automatic

AF, APCAPACITY, Refill*:

3.8 Liters 4.0 Quarts Type.............................................................................................................................................................................................................................. All ................................................................................................................................................................................................

*With the engine at operating temperature, shift transmission through all gears. Check fluid level in PARK and add fluid as needed.

> Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Transaxle/Transmission - Automatic > Page 227

Fluid - A/T: SpecificationsInitial Refill Capacity




> Maintenance > Fluids > Fluid - M/T > Component Information > Specifications

Fluid - M/T: Specifications

GL-4CAPACITY, Refill:

2.1 Liters 4.4 Pints Type......................................................................................................................................................................................................80W, 75W-85W 4-speed RWD...................................................................................................................................................................................

2.3 Liters 4.8 Pints 5-speed RWD...................................................................................................................................................................................

> Maintenance > Fluids > Fluid - Differential > Component Information > Specifications

Fluid - Differential: Specifications

GL-5* Limited-Slip ..................................................................................................................................................................................................................

GL-5 Other ...............................................................................................................................................................................................................................

CAPACITY, Refill:

1.1 Liters 2.3 Pints Above -10F (-23C), 90, 85-W-90, 80W-90; -30 to -10F (-34 to -23C), 80W, 80W-90; below -30F (-34C), 75W Front ................................................................................................................................................................................................

1.5 Liters 3.2 Pints Rear .................................................................................................................................................................................................

LIMITED-SLIP IDENTIFICATION:Lift rear of vehicle, turn one wheel and the other will turn in the same direction

> Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications

Fluid - Transfer Case: Specifications


2.2 Liters 4.6 Pints Type......................................................................................................................................................................................................80W, 75W-85W All models .......................................................................................................................................................................................

> Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - New `SG' Level Oil

Engine Oil: Technical Service BulletinsEngine 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 oilscan provide significant improvements concerning sludge, varnish and wear control. These new quality oils may also be used in older vehicles wherelower 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 manyautomotive supply outlets.


> Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - New `SG' Level Oil > Page 241

Engine Oil: Technical Service BulletinsEngine - 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-CMopar 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 providesbetter engine starting and faster lubrication to engine components at low temperatures than 10W30 or 15W40 oils. 5W-30 oil also provides betterfuel 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 atany temperature (police vehicles).

The part numbers for Mopar "Max" oil are:

5W-30 SF/CC (quart)

5W-30 SF/CC (drum)

PN 4318075

PN 4318076

5W-30 oil is now used as the factory fill in most Chrysler Corporation vehicles.


> Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Page 242

Engine Oil: Specifications

SE, SF, SG Type Gasoline engine ............................................................................................................................................................................................


2-wheel drive:

3.5 Liters 3.7 Quarts 4.5 Liters 4.7 Quarts 2.0-liter eng. ............................................................................................................................................................................2.6-liter eng. ............................................................................................................................................................................

4-wheel drive:

4.5 Liters 4.7 Quarts 5.3 Liters 5.6 Quarts 2.0-liter eng.............................................................................................................................................................................2.6-liter eng.............................................................................................................................................................................

Capacity shown is without filter. When replacing filter, additional oil may be needed

Gasoline engines:1981

1982-84 Above 32F (0C) .........................................................................................................................................................................20W-20, 20W-40, 20W-50Above -10F (-23) .......................................................................................................................................................................10W-30, 10W-40, 10W-50Below 32F (0C) .........................................................................................................................................................................................................5W-40Below 10F (-12C) ................................................................................................................................................................................5W-20, 5-30, 5W-40

Above 32F (0C) .........................................................................................................................................................................20W-20, 20W-40, 20W-50Above -10F (-23) .......................................................................................................................................................................10W-30, 10W-40, 10W-50Below 60F (16C) ...........................................................................................................................................................................5W-20*, 5W-30, 5W-40*Not recommended for sustained high-speed driving

> Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications

Refrigerant: Capacity Specifications

A/C Refrigerant Specifications

Capacity .................................................................................................................................................................................................... 34 oz (2.13 lbs)

> Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 247

Refrigerant: Fluid Type Specifications

Fluid Type specifications

Type ................................................................................................................................................................................................. Refrigerant 12 (R-12)

> Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions

Fuse Block: Diagram Information and Instructions

Group Index

Alphabetic Index to Wiring Diagrams Electrical When trying to find the diagram for a specific component or system, use the information or the under

Group Index Diagrams By Sheet Number

Diagrams By Figure Number Whenever a reference exists to another sheet or figure, find the corresponding diagram using the , , or . The reference number for the subsequent diagram will match a listed group shown.

> Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 253

Fuse Block: Electrical Diagrams

TRUCKFuse Block..............................................Left Kick Panel Below Hood Release

Fusible Link...........................................Battery Positive Terminal

> Maintenance > Service Reminder Indicators > System Information > Service Precautions

Service Reminder Indicators: Service Precautions

SERVICE PRECAUTION

All Service Reminder Indicators should be investigated or serviced immediately. Vehicle damage may result if the indicator is ignored.

> Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Adjustments

Wheel Bearing: Adjustments

Install hub bearings on spindle, then install hub nut and torque to 22 ft. lbs. to seat bearings. Loosen hub nut, then torque nut to 6 ft. lbs. Install nutretainer cap and cotter pin. If cotter pin holes are not aligned, loosen nut to align holes. The nut may be loosened to a maximum of 30 to align cotterpin holes. Check to ensure hub assembly rotates freely without play.

> Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Removal

Wheel Bearing: Service and RepairRemoval

Fig. 8 Hub & wheel bearing assembly exploded view. Shown w/manual locking hub

Fig. 9 Automatic (free wheeling) locking hub

> Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Removal > Page 263

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

1. Remove wheel and tire assembly, then remove brake caliper assembly leaving brake hose connected. Suspend caliper assembly from frame using a wire hook to prevent damage to brake hose.

2. Place hub in free position, then remove free wheeling hub cover. On models with automatic locking hubs, ensure hub is in "free wheeling" position by placing transfer case lever in 2H position and moving in reverse 4-7 feet. If cover cannot be removed by hand, loosen cover with suitable strapwrench, taking care not to damage cover.

3. Remove snap ring securing drive axle, then the adjusting shims.4. Remove free wheeling hub assembly from front hub, using tool MD998360 or equivalent to remove bolts securing automatic locking hub.

Fig. 10 Spindle nut removal & installation

5. Remove lock washer, then remove hub locknut using tool No. MB990954.6. Pull front hub with brake disc from knuckle, using care not to drop outer wheel bearing inner race.7. Remove grease from inside front hub, then using a suitable drift, drive bearing races from hub.8. Place alignment marks on brake disc and hub, then separate hub and disc as necessary.


Wheel Bearing: Service and RepairInspection

HUB, SPINDLE & BEARINGS

1. Clean components with suitable solvent and blow dry with compressed air.

Fig. 11 Checking spindle for wear

2. Inspect spindle for wear and damage and measure spindle bearing seating area diameter. Diameter should be 1.7805 to 1.7812 inch.3. Inspect bearings for damage excessive wear, overheating and scoring, and replace as needed.4. Check fit of bearing outer races in hub. If races are loose, hub should be replaced.

MANUAL LOCKING HUB


1. Inspect hub ring, inner hub and hub body, and the clutch. If components are damaged or worn, assembly should be replaced.2. Inspect tension spring and compression spring, and replace if collapsed or deteriorated.3. Check operation of control handle and replace as needed.


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)


AUTOMATIC LOCKING HUB

DISASSEMBLY

1. Press in on brake B, then remove housing C-ring.2. Remove brake B, brake B and brake spring from housing, then remove housing snap ring.3. Mount assembly in press, lightly compress drive gear, then remove retainer B C-ring, noting the following: a. Place protective cloth under cover mating surface.b. Because return spring is approximately 1.57 inches long, ensure press stroke is more than 1.57 inches.c. Do not apply more than 441 lbs. pressure to drive gear.d. After removing C-ring, slowly reduce press force until return spring relaxes completely.

4. Remove retainer B, return spring, slide gear assembly and drive gear assembly from housing.5. Remove and discard drive gear snap ring.6. Press in on slide gear cam and remove slide gear C-ring.

INSPECTION

1. Check slide and drive gear splines for damage.2. Check cam portion of retainer A for wear or damage.3. Check cam for wear and damage.4. Check slide gear and housing tooth surfaces for wear and damage.5. Check retainer B and housing contact surfaces for wear and damage.6. Check brake wear as follows:

Fig. 12 Measuring brake assembly. Automatic locking hub a. Assemble brake A and brake B, then measure thickness of assembly at two lugs on brake A.b. Standard thickness is 0.413 inch and minimum thickness is 0.378 inch.


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

7. Inspect return and shift springs as follows:

Fig. 13 Measuring spring free length. Automatic locking hub a. Measure free length of spring as shown.b. Minimum return spring free length is 1.38 inches.c. Minimum shift spring free length is 1.18 inches.

8. Replace any components that are damaged, excessively worn, or that are not within specifications.

ASSEMBLY

Apply Mopar grease 2525035 or equivalent to mounting surfaces of all components and reverse disassembly procedure, noting the following:1. Pack grooves of retainer B with specified grease.2. Install return spring with smaller diameter coil toward cam.3. Pack grooves of brake B with specified grease.


Wheel Bearing: Service and RepairInstallation

1. Drive outer races into front hub using a suitable drift, then evenly coat inner wall of front hub with grease.2. Pack inner and outer bearings with suitable grease. Apply grease to oil seal lip.3. Position inner bearing and oil seal on hub, then install oil seal using tool No. MB990985.


Fig. 14 Checking front hub rotating torque

4. If removed, install brake disc on front hub, tightening attaching bolts alternately and evenly to 36-44 ft. lbs. After assembling, check brake disc runout. Brake disc runout should not exceed 0.006 inch.

5. Carefully install front hub on steering knuckle spindle.6. Install outer bearing on spindle, then install spindle nut.7. Adjust wheel bearings as follows: a. Torque bearing locknut to 94-145 ft. lbs. while rotating hub to seat bearings.b. Loosen spindle nut and retighten to 18 ft. lbs., then back off 30.c. Install lock washer. If hole in lock washer is not aligned with hole in spindle nut, the nut may be loosened up to an additional 20 to obtain


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

proper alignment.

d. Using a suitable spring scale or torque wrench, measure force required to rotate front hub.e. The force required to rotate the front hub assembly should be 1.1-4.0 lbs. (spring scale) or 3-11 inch lbs. (torque wrench), and endplay should be less than 0.002 inch. If rotating force is not within specifications, repeat adjustment.

f. When adjustment is correct, secure washer with retaining screws.

8. On models with automatic locking hubs, measure brake contact surface depth as follows:

Fig. 15 Measuring brake contact surface depth. Automatic locking hub a. Measure dimension A, in two places using suitable depth gauge.b. Average of two readings should be 0.46-0.48 inch. If depth is greater than specified, install suitable shims. If depth is less than specified, recheck hub and bearing installation.

9. Apply grease to inner surface of free wheeling hub body assembly.

10. Apply semi-dry sealant to front hub surface to which the free wheeling hub body assembly is attached.11. Align tab on free wheel hub with groove on spindle, install free wheeling hub body assembly on front hub, then torque attaching bolts to 37-43 ft.

lbs.

12. Reverse remaining procedure to complete installation.

> Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Rear Axle Shaft - Retaining Nut Lock Washers

Axle Nut: Technical Service BulletinsRear Axle Shaft - Retaining Nut Lock Washers

Models

1979-89 PB/B4 And SJ/B6 Vehicles

Subject

Lock Washer For Rear Axle Shaft Retaining Nut

Index

REAR AXLE

Date

April 17, 1989

No.

03-01-89

(CO0-02-9)

AXLE SHAFT RETAINING NUT LOCK WASHER

BODY CODE LEGEND

PB/B4 - RAM 50 PICKUP SJ/B6 - RAM RAIDER

AXLE SHAFT RETAINING NUT LOCK WASHER

When axle service requires removal of the axle shaft retaining nut and lock washer (Figure 1), the lock washer must not be reused. The lock washer, P/NMB092433, must be replaced when reassembling the axle.

> Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Locking Hubs - Racheting Noise

Wheel Hub (Locking): Technical Service BulletinsAutomatic Locking Hubs - Racheting Noise

Models

1984-1985 Dodge Power Ram 50 Pick-Up

Subject

Racheting Noise in Automatic Locking Hubs

Index

FRONT AXLE

Date

November 19, 1984

No.

02-10-84 P-5120-CSYMPTOM/CONDITION

Racheting noise in automatic locking hubs during low temperature operation or after shifting from "4H" to "2H".

DIAGNOSIS/CORRECTION

Use the attached chart to determine the corrective action necessary.

POLICY: Information Only

SYMPTOM RESOLUTION

Noise is generated after start-up with shift lever in "2H" position under low temperature.

free-wheeling hub.

Noise is generated after shift lever is changed from "4H"

(lock) "2H" (free) position.

Drive the vehicle with the lever in "4H" position for a while to warm up oil in transfer case and then drive with the lever in "2H" position.

When shifting "4H" (lock) to

"2H" (free) position, first stop vehicle, change shift lever from "4H" to "2H" position, and then slowly drive vehicle straight backward for 10 to 20 feet.

CAUSE

Under low temperature, oil in transfer case gets stiff and it accordingly rotates front drive shaft which causes racheting effect* of automatic

If shifting is done while vehicle is turning, only one side of free-wheeling hub will be freed resulting in the racheting effect.*

*Racheting effect is caused when slide gear and housing gear are not engaged and there is difference of revolution speed between those two gears. Noiseis caused by this revolutional difference.

The racheting of the hubs is not detrimental to the components or operation of the vehicle. The 1985 owners manual will advise the customer of thecondition.

> Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications


Pressure 170 psi

> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications

Camshaft: Specifications

Cap Bolt Torque 14-15 ft.lb

> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 287

Camshaft: Service and Repair

Removal

1.

Disconnect battery ground cable and remove air cleaner.

2.

Disconnect spark plug wires and remove accessory drive belts, as needed.

3.

Mark and disconnect necessary electrical connectors and vacuum hoses, then remove timing belt upper cover and rocker arm cover.

Fig. 5 Camshaft timing marks. 2000cc engine

4.

Rotate crankshaft in normal direction of rotation until No. 1 cylinder is at TDC and crankshaft and camshaft timing marks are aligned,.

5.

6.

Do not rotate crankshaft after sprocket is removed from camshaft.

Place chalk mark between timing belt and camshaft sprocket, remove camshaft sprocket bolt, separate sprocket from camshaft leaving belt in placeon sprocket, then secure sprocket and belt on lower timing cover. Take care that sprocket does not disengage from belt and fall, and maintaintension on belt to maintain proper timing.

Evenly loosen camshaft bearing cap/rocker arm retaining bolts in crossing pattern, remove bearing caps and rocker shafts as an assembly, thenremove camshaft.


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

Fig. 21 Rocker arms, rocker shafts & camshaft exploded view. 2000cc engines

7.

Fig. 21, Disassemble components in numerical order, noting position for installation.

Installation

1.

Coat camshaft with suitable assembly lubricant and position cam in head, with camshaft aligned so that valves for No. 1 cylinder are closed (TDCon compression stroke).

Fig. 17 Rocker arm shaft installation, 1600cc, 2000cc engines

2.

Fig.17. Insert rocker shafts into front bearing cap, installing shaft with oil hole side down and noting that front end of shaft has a cut .16 inch wide,


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

Fig. 22 Assembling rocker arms & rocker arm shafts. 2000cc engine

3.

Fig. 22,

Apply engine oil to I.D. of rocker arms prior to assembly. Assemble rocker arms, springs and remaining bearing caps on rocker shafts, inpositions noted during disassembly.

Fig. 23 Hydraulic lash adjuster & retaining clip installation. 1985-88 2000cc & 2600cc engines

4.

Fig. 23, On models with hydraulic lash adjusters, insert each adjuster into rocker arm taking care not to spill fluid from adjuster. Retain adjusters usingsuitable clips, to prevent them from falling out during installation.

5.

On all models, install assembly onto cylinder head and evenly tighten bolts in crossing pattern until bearing caps are seated. When caps are seated,torque bolts to specifications in crossing pattern.

6.

Install sleeve over camshaft and press oil seal into place using suitable driver.

7.

Install camshaft sprocket and timing belt, then ensure timing marks are properly aligned.

8.

Adjust valves to specifications as outlined, then temporarily install rocker cover.

9.

Reverse remaining procedure to complete installation, then check timing belt tension as outlined. After engine reaches normal operatingtemperature, recheck valve clearances and adjust as needed.

Fig. 24 Applying sealant to semi-circular packing

10.

Fig. 24,

When installing rocker cover after checking valve clearances, apply suitable sealer to semi-circular packing and cylinder head, then installrocker cover.

> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair

Rocker Arm Assembly: Service and Repair

REMOVAL

1. Disconnect battery ground cable and remove air cleaner.2. Disconnect spark plug wires and remove accessory drive belts, as needed.3. Mark and disconnect necessary electrical connectors and vacuum hoses, then remove timing belt upper cover and rocker arm cover.


Fig. 5. 4. Rotate crankshaft in normal direction of rotation until No. 1 cylinder is at TDC and crankshaft and camshaft timing marks are aligned, 5. Place chalk mark between timing belt and camshaft sprocket, remove camshaft sprocket bolt, separate sprocket from camshaft leaving belt in place


on sprocket, then secure sprocket and belt on lower timing cover. Take care that sprocket does not disengage from belt and fall, and maintaintension on belt to maintain proper timing.

6. Evenly loosen camshaft bearing cap/rocker arm retaining bolts in crossing pattern, remove bearing caps and rocker shafts as an assembly, then remove camshaft.

> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 293

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)


Fig. 21, 7. Disassemble components in numerical order, noting position for installation.

INSTALLATION

1. Coat camshaft with suitable assembly lubricant and position cam in head, with camshaft aligned so that valves for No. 1 cylinder are closed (TDC on compression stroke).


Fig.

2. Insert rocker shafts into front bearing cap, installing shaft with oil hole side down and noting that front end of shaft has a cut .16 inch wide,

17.


Fig. 22, 3. Apply engine oil to I.D. of rocker arms prior to assembly. Assemble rocker arms, springs and remaining bearing caps on rocker shafts, in positions noted during disassembly.


4. On models with hydraulic lash adjusters, insert each adjuster into rocker arm taking care not to spill fluid from adjuster. Retain adjusters using

Fig. 23, suitable clips, to prevent them from falling out during installation.

5. On all models, install assembly onto cylinder head and evenly tighten bolts in crossing pattern until bearing caps are seated. When caps are seated,

> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 294

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

torque bolts to specifications in crossing pattern.

6. Install sleeve over camshaft and press oil seal into place using suitable driver.7. Install camshaft sprocket and timing belt, then ensure timing marks are properly aligned.8. Adjust valves to specifications as outlined, then temporarily install rocker cover.9. Reverse remaining procedure to complete installation, then check timing belt tension as outlined. After engine reaches normal operating temperature, recheck valve clearances and adjust as needed.


Fig. 24, 10. When installing rocker cover after checking valve clearances, apply suitable sealer to semi-circular packing and cylinder head, then install rocker cover.

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Service and Repair

Connecting Rod Bearing: Service and Repair

Fig. 50 Piston & rod assembly

Fig. 50.

This piston and rod is assembled with the indented arrow on the piston and the embossed numeral on the rod facing toward front of engine,

PISTON, PINS & RINGS

0.010, 0.020, 0.030 and 0.039 inch Pistons and rings are available in standard size and oversizes of . Oversize pins are not available.

MAIN & ROD BEARINGS

0.010, 0.020 and 0.030 inch Main and rod bearings are available in undersizes of .

The main bearing caps are installed with arrows facing front of engine.

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications

Connecting Rod: Specifications

Connecting Rod Cap Bolts 33-34 ft.lb

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 302

Connecting Rod: Service and Repair


Fig. 50.







> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair

Crankshaft Main Bearing: Service and Repair


Fig. 50.







> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Crankshaft Journal Tolerances

Crankshaft: Specifications

Rod Journal Diameter 1.772 in

Main Journal Diameter 2.244 in

Shaft End Play 0.002-0.007 in

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Crankshaft Journal Tolerances > Page 310

Crankshaft: Specifications

Crankshaft Main Bearing Caps 61 ft.lb

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer - Crankshaft Pulley > Component Information > Technical Service Bulletins > Engine - Torque Specifications, Manual Correction

Harmonic Balancer - Crankshaft Pulley: Technical Service BulletinsEngine - Torque Specifications, Manual Correction

Models

1984 Ram 50, Power Ram 50

Subject

Service Manual Correction Engine Torque Specifications

Index

ENGINE

Date July 30, 1984

No.

09-10-84

P-3050-C

FIGURE 1

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer - Crankshaft Pulley > Component Information > Technical Service Bulletins >

Engine - Torque Specifications, Manual Correction > Page 315

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

Errors in the tightening torques for the engine crankshaft pulley shown in the 1984 Ram 50 Service Manual, Publication #81-370-4009, have beencorrected as described in Figures 1 and 2.

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer - Crankshaft Pulley > Component Information > Technical Service Bulletins > Page 316

Harmonic Balancer - Crankshaft Pulley: Specifications

Vibration Damper Or Pulley 11-15 ft.lb

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications

Piston: Specifications

Piston Clearance .0008-.0016 in

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 320

Piston: Service and Repair


Fig. 50.







> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications

Piston Ring: Specifications

Ring End Gap Top Ring 0.010 in

Note: Fit rings in tapered bores for clearance listed in tightest portion of ring travel.

2nd Ring 0.008 in

Oil Ring 0.008 in

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 324

Piston Ring: Service and Repair


Fig. 50.







> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications




Jet Valve

Exhaust 0.01 in

Intake 0.006 in

> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 329






Fig. 12.




JET VALVE



Fig. 13.


> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair

Rocker Arm Assembly: Service and Repair

REMOVAL

1. Disconnect battery ground cable and remove air cleaner.2. Disconnect spark plug wires and remove accessory drive belts, as needed.3. Mark and disconnect necessary electrical connectors and vacuum hoses, then remove timing belt upper cover and rocker arm cover.


Fig. 5. 4. Rotate crankshaft in normal direction of rotation until No. 1 cylinder is at TDC and crankshaft and camshaft timing marks are aligned, 5. Place chalk mark between timing belt and camshaft sprocket, remove camshaft sprocket bolt, separate sprocket from camshaft leaving belt in place


on sprocket, then secure sprocket and belt on lower timing cover. Take care that sprocket does not disengage from belt and fall, and maintaintension on belt to maintain proper timing.

6. Evenly loosen camshaft bearing cap/rocker arm retaining bolts in crossing pattern, remove bearing caps and rocker shafts as an assembly, then remove camshaft.

> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 333

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)


Fig. 21, 7. Disassemble components in numerical order, noting position for installation.

INSTALLATION

1. Coat camshaft with suitable assembly lubricant and position cam in head, with camshaft aligned so that valves for No. 1 cylinder are closed (TDC on compression stroke).


Fig.

2. Insert rocker shafts into front bearing cap, installing shaft with oil hole side down and noting that front end of shaft has a cut .16 inch wide,

17.


Fig. 22, 3. Apply engine oil to I.D. of rocker arms prior to assembly. Assemble rocker arms, springs and remaining bearing caps on rocker shafts, in positions noted during disassembly.


4. On models with hydraulic lash adjusters, insert each adjuster into rocker arm taking care not to spill fluid from adjuster. Retain adjusters using

Fig. 23, suitable clips, to prevent them from falling out during installation.

5. On all models, install assembly onto cylinder head and evenly tighten bolts in crossing pattern until bearing caps are seated. When caps are seated,

> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 334

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

torque bolts to specifications in crossing pattern.

6. Install sleeve over camshaft and press oil seal into place using suitable driver.7. Install camshaft sprocket and timing belt, then ensure timing marks are properly aligned.8. Adjust valves to specifications as outlined, then temporarily install rocker cover.9. Reverse remaining procedure to complete installation, then check timing belt tension as outlined. After engine reaches normal operating temperature, recheck valve clearances and adjust as needed.


Fig. 24, 10. When installing rocker cover after checking valve clearances, apply suitable sealer to semi-circular packing and cylinder head, then install rocker cover.

> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications

Valve Cover: Specifications

Rocker Arm Cover 4-5 ft/lb ft.lb

> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Service and Repair

Valve Guide: Service and Repair

Fig. 29 Valve guide & guide bore oversizes

1.

2.

3.

Press old valve guide from cylinder head toward lower surface using pushrod from valve guide replacement kit, tool No. MD998115 and a suitablepress.

Fig. 29.

Ream each valve guide bore in cylinder head to the O.D. of replacement valve guide,

4.

Press fit new valve guide into top of cylinder head using tool No. MD998115. This tool installs valve guide to a predetermined height. If astandard size valve guide has been removed, replacement valve guide should be oversized. New valve guide should be installed at roomtemperature.

After installation of new valve guides, insert valve and check for proper clearance. If clearance is not correct, ream guide until proper clearance isobtained. Refer to ``Valve Specifications'' for stem to guide clearance.

> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications

Valve Seat: SpecificationsSeat Angle

Seat Angle

Valve Seat Angle 45 deg

> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications

Valve Spring: SpecificationsSpring Height and Pressure

Spring Height and Pressure

Installed Height 1.590 in

Note: Jet valve spring installed height, .846 inch.

Valve Spring Pressure 62 lbf at 1.591 in

> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications

Valve: Specifications

Valve Face Angle 45 deg

Stem Clearance Intake .0012-.0024 in

Exhaust .0020-.0035 in

Stem Diameter Intake 0.315 in

Exhaust 0.315 in

Jet Valve 0.1693 in

> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications

Drive Belt: Specifications

1981-84 ex. Diesel: One-fourth of a inch or 6-10 millimeter deflection at midpoint of belt between water pump & alternator, under a 22 lb load.

> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - New `SG' Level Oil

Engine Oil: Technical Service BulletinsEngine 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 oilscan provide significant improvements concerning sludge, varnish and wear control. These new quality oils may also be used in older vehicles wherelower 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 manyautomotive supply outlets.


> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - New `SG' Level Oil > Page 359

Engine Oil: Technical Service BulletinsEngine - 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-CMopar 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 providesbetter engine starting and faster lubrication to engine components at low temperatures than 10W30 or 15W40 oils. 5W-30 oil also provides betterfuel 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 atany temperature (police vehicles).

The part numbers for Mopar "Max" oil are:

5W-30 SF/CC (quart)

5W-30 SF/CC (drum)

PN 4318075

PN 4318076

5W-30 oil is now used as the factory fill in most Chrysler Corporation vehicles.


> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Page 360

Engine Oil: Specifications

SE, SF, SG Type Gasoline engine ............................................................................................................................................................................................


2-wheel drive:

3.5 Liters 3.7 Quarts 4.5 Liters 4.7 Quarts 2.0-liter eng. ............................................................................................................................................................................2.6-liter eng. ............................................................................................................................................................................

4-wheel drive:

4.5 Liters 4.7 Quarts 5.3 Liters 5.6 Quarts 2.0-liter eng.............................................................................................................................................................................2.6-liter eng.............................................................................................................................................................................

Capacity shown is without filter. When replacing filter, additional oil may be needed

Gasoline engines:1981

1982-84 Above 32F (0C) .........................................................................................................................................................................20W-20, 20W-40, 20W-50Above -10F (-23) .......................................................................................................................................................................10W-30, 10W-40, 10W-50Below 32F (0C) .........................................................................................................................................................................................................5W-40Below 10F (-12C) ................................................................................................................................................................................5W-20, 5-30, 5W-40

Above 32F (0C) .........................................................................................................................................................................20W-20, 20W-40, 20W-50Above -10F (-23) .......................................................................................................................................................................10W-30, 10W-40, 10W-50Below 60F (16C) ...........................................................................................................................................................................5W-20*, 5W-30, 5W-40*Not recommended for sustained high-speed driving

> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Oil Filter - Addition of Second Supplier

Oil Filter: Technical Service BulletinsOil Filter - Addition of Second Supplier

Models

1984 Colt, Vista, Conquest, D-50 Pick-Up Except With Diesel Engines

Subject

Addition of Second Oil Filter Supplier

Index

ENGINE

Date

December 10, 1984

No.

09-12-84Beginning in July, 1984, MMC began using a second supplier for oil filters in production on all car lines except D-50 pick-up trucks equipped withdiesel engines. The alternate filter is identified by PN

MD084963.

For service parts, use the present replacement filter, PN MD031805, as a replacement for either MD084963 or MD031805.


> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Housing > Component Information > Technical Service Bulletins > Oil Filter Bracket & Oil Pump - Modification

Oil Filter Housing: Technical Service BulletinsOil Filter Bracket & Oil Pump - Modification

Models

1984-1987 NF45Z (Colt Vista) & PB (Ram 50) With 2.0L Engine

Subject

Modification of Oil Pump & Oil Filter Bracket

Index

ENGINE

Date

June 29, 1987

No.

09-05-87 (C2-09)

P-2315SYMPTOM/CONDITION

The oil pump gears, oil pump cover, and oil filter bracket assembly for the subject model vehicles have been modified, effective with vehicles producedsince November, 1986, as follows:

1

1

1

1

Rear Wheel Drive - Engine #FC8526 and beyond Front Wheel Drive - Engine #FC8530 and beyond

Following are the replacement parts for servicing these modified oil pumps:

Oil Pump Drive Gear

Oil Pump Driven Gear

Front Case Assembly

Oil Filter Bracket Assembly:

Ram 50

Vista

PN MD096269

PN MD041089

PN MD102415

PN MD122260

PN MD122261

These parts can be used on earlier built engines if both gears, front case assembly, and oil filter bracket assembly are replaced together.


> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair

Oil Pan: Service and Repair

On some models it may be necessary to remove engine from vehicle to gain access to oil pan.

1.

Raise and support vehicle, remove engine splash pan, if equipped, then drain crankcase.

2.

Remove the oil pressure sender unit, if necessary, and on turbocharged models, disconnect oil drain hose and remove oil drain pipe.

3.

Remove the oil pan bolts and oil pan.

4.

Remove oil pump pickup if necessary.

5.

Reverse procedure to install.

> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Technical Service Bulletins > Oil Filter Bracket & Oil Pump - Modification

Oil Pump: Technical Service BulletinsOil Filter Bracket & Oil Pump - Modification

Models

1984-1987 NF45Z (Colt Vista) & PB (Ram 50) With 2.0L Engine

Subject

Modification of Oil Pump & Oil Filter Bracket

Index

ENGINE

Date

June 29, 1987

No.

09-05-87 (C2-09)


The oil pump gears, oil pump cover, and oil filter bracket assembly for the subject model vehicles have been modified, effective with vehicles producedsince November, 1986, as follows:

1

1

1

1

Rear Wheel Drive - Engine #FC8526 and beyond Front Wheel Drive - Engine #FC8530 and beyond

Following are the replacement parts for servicing these modified oil pumps:

Oil Pump Drive Gear

Oil Pump Driven Gear

Front Case Assembly

Oil Filter Bracket Assembly:

Ram 50

Vista

PN MD096269

PN MD041089

PN MD102415

PN MD122260

PN MD122261

These parts can be used on earlier built engines if both gears, front case assembly, and oil filter bracket assembly are replaced together.


> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Technical Service Bulletins > Page 376

Oil Pump: Service and Repair

To remove oil pump pickup, refer to `Òil Pan, Replace.''

Fig. 54 Oil pump assembly. 2000cc engines

The oil pump is of the gear type. The oil pump is also used to drive the left counterbalance shaft. The oil pump drive gear has a sprocket driven by a timing belt. The counterbalance shaft is mounted to the oil pump driven gear and rotates in the opposite direction of crankshaft rotation.

1.

Remove timing case as outlined under ``Timing Case, Replace'' procedure.

2.

Remove oil pump gears and left counterbalance shaft from case.

Fig. 55 Oil pump gear timing marks. 2000cc engines

3.

Install oil pump gear in timing case, aligning timing marks.

4.

Insert left counterbalance shaft into driven gear.

5.

Install timing case.

> Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications

Intake Manifold: Specifications

Intake Manifold 11-14 ft.lb

> Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair

Crankshaft Main Bearing Seal: Service and Repair

Fig. 51 Disassembled view of rear seal

1.

Remove transmission, clutch assembly and flywheel or flex plate, as equipped.

2.

Fig. 51.

Remove rear oil seal case and separate into three parts: oil seal, separator and case,

Fig. 52 Installing rear seal into case

3.

Fig. 52.

Drive in oil seal from inside of case, using suitable tool, Ensure the oil seal plate fits properly in the inner contact surface of the seal case,if equipped.

4.

Install separator with the oil hole facing the bottom of the case, if equipped.

5.

Apply engine oil to oil seal lips.

6.

Install the oil seal case in the cylinder block.

> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Adjustments

Timing Belt: Adjustments

1. Remove timing belt front upper cover.2. Carefully check the timing belt on its whole circumference for cracks and peeling.3. Turn crankshaft in normal direction (clockwise) until timing mark on camshaft sprocket is aligned with mating mark on cylinder head, so that piston in No. 1 cylinder is placed at top dead center on compression stroke.

CAUTION:

Do not turn crankshaft in opposite direction (counterclockwise) to align the timing mark with mating mark, otherwise an improper timing belt tension could result.

Timing Marks

4. Turn crankshaft in normal direction (clockwise) until second tooth past timing mark (punch) position on camshaft sprocket should be aligned with timing mark on cylinder head.

Access Cover Location

Removing Access Cover

5. Remove two access covers. Access cover can be easily removed by inserting screwdriver into groove from direction of embossed arrow and pry.6. Insert wrench through adjusting hole and loosen timing belt tensioner tightening bolt and nut.

CAUTION: 180 to 200 Loosen bolt and nut . If they are loosened more than necessary, they might fall into cover.

7. Insert plain screwdriver from top of timing belt cover. Slightly push tensioner bracket in tensioning direction, and then release. Now belt tension

> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Adjustments > Page 388

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

will be automatically adjusted by tensile strength of tensioner spring.

CAUTION:

The purpose of pushing tensioner with screwdriver is to loosen tensioner mounting surface which might have stuck due to manyhours of being tightened

8. First tighten tensioner mounting bolt (bottom side) with wrench and then tighten mounting nut (top side).

CAUTION: Make sure that bolt (bottom side) is tightened first. If nut is tightened first, belt tension will vary (will become too tight).

Mounting Access Cover

9. Mount two access covers to respective adjusting holes. Access cover can be easily mounted by sliding in such a way that hook will pass between guide projections.

10. Install timing belt front upper cover.


Timing Belt: Service and Repair

Timing Belt Train

REMOVAL

Remove the parts in numerical order shown, paying attention to the following items.1. Place piston of No. 1 cylinder at top dead center of compression stroke.


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

Securing Tensioner Temporarily

2. Move tensioner fully toward water pump and temporarily secure it.3. If timing belt is to be reused, make an arrow mark which indicates turning direction to ensure that belt is reinstalled in same direction as before.


4. When oil pump sprocket nut is removed, first remove plug at left side of cylinder block and insert a screwdriver to keep left silent shaft in position.

8 mm (.3 in.) 60 mm (2.36 in) Screwdriver used for this purpose should have a shaft thick which can be inserted more than .

Removing Timing Belt B

5. Loosen right silent shaft sprocket mounting bolt unit it can be loosened by hand.6. Next, remove tensioner "B" and remove timing belt "B".

CAUTION: After timing belt "B" has been removed, do not attempt loosening bolt, while holding sprocket with pliers, etc.

INSPECTION

1. Check belt in detail if following flaws are evident, replace belt with a new one.

Checking Timing Belt a. Hardened back surface rubber back surface glossy. Nonelastic and so hard that even if a finger nail is forced into it, no mark is produced.


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

Checking Timing Belt b. Cracked back surface rubberc. Cracked or exfoliated canvasd. Cracked tooth bottome. Side of belt crackedf.

g. Side of belt badly worn

NOTE: Normal belt should have clear-cut sides as if cut with a sharp knife.

h. Badly worn teeth

Initial stage: Canvas on load side tooth flank worn (fluffy canvas fibers, rubber gone and color changed to white, and unclear canvas texture).Last stage: Canvas on load side tooth flank worn down and rubber exposed (tooth width reduced).

i. Missing tooth.

INSTALLATION

1. Install crankshaft sprocket, flange and spacer as shown, while paying attention to their mounting directions.

CAUTION: Pay special attention to direction of flange. If it is installed in wrong direction, a broken belt could result.

2. Temporarily secure tensioner at a position closest to water pump.3. install end A of spring to predetermined position on tensioner bracket.4. Install end B of spring to predetermined position on water pump.5. When spacer is installed to right silent shaft, direct spacer with its chamfered end toward shaft for protection of oil seal.

BELT INSTALLATION PROCEDURE

Aligning Timing Marks

1. Align timing mark on each sprocket with corresponding timing mark on front case.2. When timing belt "B" is installed, make certain that tension side has no slack.


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

Installing Tensioner "B"

3. install tensioner "B" with center of pulley located on left side of mounting bolt and with pulley flange directed toward front of engine.

Adjusting Belt Tension

4. Lift tensioner "B" with finger tip to tighten timing belt "B" so that its tension side will be taut. in this condition tighten bolt to secure tensioner

"B". When bolt is tightened, use care to prevent shaft from turning together. If shaft is turned together, belt will be overtensioned.

specification.

Belt deflection 5 to 7 mm (.2 to .3 in.) ..................................................................................................................................................................................

7. Move tensioner fully toward water pump and temporarily secure tensioner.

5. Check to ensure that timing marks are in alignment.6. Check to ensure that when center of span on tension side is depressed with index finger in direction of arrow, deflection of belt is up to

Mounting Timing Belt


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

8. Align timing mark on camshaft sprocket with that on cylinder head.9. Align timing mark on crankshaft sprocket with that on front case.

10. Align timing mark on oil pump sprocket with that on front case.


11. When timing mark on oil pump pulley is aligned with that on front case, be sure to remove plug on left side of cylinder block and insert a screw

8 mm (.3 in.) in 60 mm (2.36 in.)

25 mm(1 in.)

60 mm (2.36in.) driver having shaft diameter. If it can be inserted or more, alignment is correct. If it can be inserted only , turn oil pump sprocket through a turn and realign timing marks. Check to ensure that screwdriver can be inserted more than . Keep screw driver inserted until installation of timing belt is finished.

12. Install timing belt. While making sure that tension side of belt is not slackened, install timing belt onto crankshaft sprocket, oil pump sprocket and camshaft sprocket in that order.

13. Loosen tensioner mounting bolt and nut. By so doing, tensioner will be moved by spring and will apply tension to belt.14. Check that portion of belt which is indicated by arrow A to make sure that it is not floating up.15. Tighten tensioner mounting nut and bolt. Tighten slot side bolt before tightening fulcrum side nut. If fulcrum side nut is tightened earlier, tension bracket will be turned together and belt will be overtensioned.

16. Check to ensure that timing marks on all sprockets are in alignment with respective timing marks.17. Turn crankshaft.

CAUTION: Do not turn crankshaft in reverse direction. Crankshaft should be turned smoothly clockwise.

18. Loosen tensioner mounting nut and bolt.19. Tighten tensioner mounting nut and bolt. Be sure to tighten fulcrum side nut and bolt in Step 15.

Adjusting Timing Belt Tension

20. Check to ensure that when center of belt span on tension side and seal line of under cover are held between thumb and forefinger as illustrated, clearance C between belt and seal line is as follows:

Clearance C Approx. 14 mm. (.55 in.) ................................................................................................................................................................................

> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Adjustments

Timing Belt Tensioner: Adjustments

Fig. 49 Positioning camshaft sprocket for timing belt adjustment. 1500cc engine, 1600cc & 2000cc engines similar

1. On Colt models, turn steering wheel all the way to left lock, support engine with suitable jack and remove left engine mount bracket to provide clearance to rotate crankshaft.

2. Remove timing belt upper front cover and the spark plugs.3. Rotate crankshaft clockwise (normal direction of rotation) and inspect timing belt. If belt is satisfactory, continue rotating crankshaft until No. 1

Cylinder is at TDC on compression stroke and timing mark on camshaft sprocket is aligned with mark on belt cover or cylinder head.

Fig. 49.

4. Rotate crankshaft clockwise until mark on camshaft sprocket is 2 teeth away from mark on cover or cylinder head, This causes spring

Do not rotate crankshaft counterclockwise, as belt tension willbe adversely affected. pressure of No. 2 exhaust valve to apply specific tension to tension timing belt.

5. Remove accessory drive belts and pulleys as needed, then the two adjusting port covers, inserting a screwdriver into slot on timing belt cover and prying timing port covers off.

Do not loosen bolt or nut more than 3/4 6. Insert 14 mm socket through adjusting port, loosen timing belt tensioner nut and bolt 1/2 - 3/4 turn. turn, as fastener may fall out into cover .

7. Check to ensure that tensioner is not sticking, by inserting a screwdriver through opening on top of lower timing belt cover and pushing tensioner toward timing belt. Release tensioner and remove screwdriver. Spring tension of the timing belt tensioner will automatically adjust the timing belt.

8. Tighten tensioner adjuster bolt, then the pivot bolt. Always tighten slotted adjuster bolt or nut first to prevent tensioner from rotating out of position.

9. Install adjusting port covers, then install timing belt upper front cover.

> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair

Timing Cover: Service and Repair

1.

Remove timing belt as described under ``Timing Belt, Replace.''

2.

Remove camshaft sprocket, crankshaft sprocket and flange.

3.

Remove timing belt tensioner.

Fig. 32 Locking left silent shaft. 2000cc engines

4.

Fig. 32.

Remove oil pump sprocket. When the oil pump sprocket nut is removed, first remove plug at bottom of left side of cylinder block, then insert asuitable screwdriver to keep the left counterbalance shaft in position,

Fig. 33 Silent shaft timing belt (B) & tensioner. 2000cc engines

5.

Fig. 33, Loosen counterbalance shaft sprocket mounting bolt then remove tensioner ``B,'' and timing belt ``B.''

6.

Fig. 33, Remove crankshaft sprocket ``B,'' and the counterbalance shaft sprocket.

7.

Remove timing belt upper under and lower under covers.

8.

Remove water pump.

9.

Remove cylinder head assembly.

10.

Remove oil pan, oil screen and oil pump cover.

> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Page 400

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

Fig. 34 Oil pump driven gear removal. 2000cc engines

11.

Fig. 34.

Insert a screwdriver through plug hole in left side of cylinder block to hold counterbalance shaft in position, then loosen oil pump driven gearmounting bolt,

12.

Remove timing case with left counterbalance shaft attached.

13.

Reverse procedure to install. Refer to ``Timing Belt or Chain, Replace'' procedure for timing belt installation.

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > By Symptom for Air/Fuel Mixture: > 140884 > Jan > 84 > Propane

Idle Set - Procedure


Models


Subject


Index

FUEL

Date

January 17, 1984

No..

14-08-84

P-94-C




1.


2.


NOTE:


3.


4.


5.


6.


7.


> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > By Symptom for Air/Fuel Mixture: > 140884 > Jan > 84 > Propane Idle Set - Procedure > Page 413

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

8.


9.





D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 3

10.


FIGURE 2


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



FIGURE 4

11.





12.


13.



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

14.


15.


16.

17.


18.


19.


20.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > All Technical Service Bulletins for Air/Fuel Mixture: > 140884 >

Jan > 84 > Propane Idle Set - Procedure


Models


Subject


Index

FUEL

Date

January 17, 1984

No..

14-08-84

P-94-C




1.


2.


NOTE:


3.


4.


5.


6.


7.


> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > All Technical

Service Bulletins for Air/Fuel Mixture: > 140884 > Jan > 84 > Propane Idle Set - Procedure > Page 423

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

8.


9.






D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 3

10.


FIGURE 2



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



FIGURE 4

11.





12.


13.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

14.


15.


16.

17.


18.


19.


20.





D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > By Symptom: > 140884 > Jan > 84 > Propane Idle Set - Procedure


Models


Subject


Index

FUEL

Date

January 17, 1984

No..

14-08-84

P-94-C




1.


2.


NOTE:


3.


4.


5.


6.


7.


> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > By Symptom: >


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

8.


9.






D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 3

10.


FIGURE 2



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



FIGURE 4

11.





12.


13.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

14.


15.


16.

17.


18.


19.


20.





D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 142084 > May > 84 >

Engine Specifications - Manual Corrections


Models


Subject


Index

FUEL

Date

May 21, 1984

No..

14-20-84

P-2112-C



> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical

Service Bulletins for Idle Speed: > 142084 > May > 84 > Engine Specifications - Manual Corrections > Page 446

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)





> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 141984 > May > 84 >

Carburetor - Idle Speed Adjustment on A/C Install


Models


Subject


Index

FUEL

Date

May 7, 1984

No.

14-19-84




1.


FIGURE 1


Service Bulletins for Idle Speed: > 141984 > May > 84 > Carburetor - Idle Speed Adjustment on A/C Install > Page 451

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

2.


FIGURE 2

3.


4.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

FIGURE 2


FIGURE 1

6.


7.


8.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)


Example:

FIGURE 2


FIGURE 2



1.


2.


3.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

4.


FIGURE 2




> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 140884 > Jan > 84 >

Propane Idle Set - Procedure


Models


Subject


Index

FUEL

Date

January 17, 1984

No..

14-08-84

P-94-C




1.


2.


NOTE:


3.


4.


5.


6.


7.



Service Bulletins for Idle Speed: > 140884 > Jan > 84 > Propane Idle Set - Procedure > Page 459

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

8.


9.






D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 3

10.


FIGURE 2



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



FIGURE 4

11.





12.


13.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

14.


15.


16.

17.


18.


19.


20.





D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > 142084 > May > 84 >

Engine Specifications - Manual Corrections


Models


Subject


Index

FUEL

Date

May 21, 1984

No..

14-20-84

P-2112-C



> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service

Bulletins for Idle Speed: > 142084 > May > 84 > Engine Specifications - Manual Corrections > Page 469

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)





> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > 141984 > May > 84 >

Carburetor - Idle Speed Adjustment on A/C Install


Models


Subject


Index

FUEL

Date

May 7, 1984

No.

14-19-84




1.


FIGURE 1


Bulletins for Idle Speed: > 141984 > May > 84 > Carburetor - Idle Speed Adjustment on A/C Install > Page 474

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

2.


FIGURE 2

3.


4.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

FIGURE 2


FIGURE 1

6.


7.


8.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)


Example:

FIGURE 2


FIGURE 2



1.


2.


3.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

4.


FIGURE 2




> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 478

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications


> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams



> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams >

Page 486

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

TIMING MARK 1981-85 5.2L & 5.9L

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Vacuum Advance Unit <--> [Distributor Advance Unit] > Component Information > Specifications > Electrical

Specifications


> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Vacuum Advance Unit <--> [Distributor Advance Unit] > Component Information > Specifications > Electrical

Specifications > Page 492

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 181788 > Oct > 88 > Spark Plugs

- Oil Fouling/Misfire on Hard Acceleration


Models


Subject


Index

FUEL

Date

October 17, 1988

No.

18-17-88


FIGURE 1

SYMPTOM/CONDITION



> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer

Interest for Spark Plug: > 181788 > Oct > 88 > Spark Plugs - Oil Fouling/Misfire on Hard Acceleration > Page 501

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2





FIGURE 1

DIAGNOSIS





PN MD009440

PN MD009786

1.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

2.



FIGURE 3

3.


a.

Remove spark plug.

b.



d.


e.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

4.


5.



> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 181788 > Oct > 88

> Spark Plugs - Oil Fouling/Misfire on Hard Acceleration


Models


Subject


Index

FUEL

Date

October 17, 1988

No.

18-17-88


FIGURE 1

SYMPTOM/CONDITION



> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical

Service Bulletins for Spark Plug: > 181788 > Oct > 88 > Spark Plugs - Oil Fouling/Misfire on Hard Acceleration > Page 509

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2





FIGURE 1

DIAGNOSIS





PN MD009440

PN MD009786

1.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

2.



FIGURE 3

3.


a.

Remove spark plug.

b.



d.


e.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

4.


5.



> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 512

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications


Pressure 170 psi

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications




Jet Valve

Exhaust 0.01 in

Intake 0.006 in

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 519






Fig. 12.




JET VALVE



Fig. 13.


> Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair

Water Pump: Service and Repair

1.

Disconnect battery ground cable and drain cooling system.

2.

Remove fan shroud, then disconnect lower radiator hose.

3.

Remove drive belt cooling fan and pulley.

4.

Place No. 1 piston at top dead center, compression stroke.

5.

Remove camshaft pulley, timing belt covers, timing belt, camshaft sprocket, upper under cover and timing belt tensioner.

6.

Remove water pump mounting bolts and the water pump.

7.


> Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Recycling Recommendations

Coolant: Technical Service BulletinsEngine Coolant - Recycling Recommendations

SUBJECT:

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 systemshave been advertised as producing a recycled antifreeze "as good as" original and suggest the recycled product is suitable for use in Chrysler Corporationvehicles.

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 likenew 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.

> Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Page 528

Coolant: Specifications

1982-89 Ram 50

* 9.0 L (9.5 qts) Cooling System Capacity .............................................................................................................................................................................

* Includes 0.65 L (0.69 qts) for the coolant reserve tank.

> Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Technical Service Bulletins > Carburetor Coolant Hose - Installation Procedure

Coolant Line/Hose: Technical Service BulletinsCarburetor Coolant Hose - Installation Procedure

Models

All 1984 Import MMC Vehicles With Carburetors Except 2.6L Engines

Subject

Correct Carburetor Coolant Hose Installation Procedure

Index

FUEL

Date

December 3, 1984

No.

14-62-84

P-5298-CThe procedure described in this bulletin should be utilized when servicing the coolant hose or carburetor for the wax pellet choke housing.

FIGURE 1

When installing the lower coolant hose on the wax pellet choke housing, the following steps should be followed to avoid interference of the tab end ofthe hose clamp with the accelerator cable (Figure 1).

1.. Lower coolant hose should only be pushed on up to the shoulder on choke housing nipple (Figure 1).

2.

Tab ends of the spring hose clamps for the lower coolant hose should be positioned downward (Figure 1).


> Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications


Switch Torque


> Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair

Heater Core: Service and Repair

Fig. 23 Heater core & blower motor. 1984-86 Ram 50

1. Disconnect battery ground cable, then place temperature control lever in Off position and drain cooling system.2. Remove parcel tray, center ventilation duct and grille and defroster duct.3. Disconnect heater hoses from heater core. Plug heater core fittings to prevent coolant spillage.4. Disconnect wire connector from blower motor.5. Remove bolts and nuts attaching heater assembly to dash panel, then the heater assembly.6. Remove heater core from heater assembly.7. Reverse procedure to install.

> Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >

Specifications


Switch Torque


> Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair

Water Pump: Service and Repair

1.

Disconnect battery ground cable and drain cooling system.

2.

Remove fan shroud, then disconnect lower radiator hose.

3.

Remove drive belt cooling fan and pulley.

4.

Place No. 1 piston at top dead center, compression stroke.

5.

Remove camshaft pulley, timing belt covers, timing belt, camshaft sprocket, upper under cover and timing belt tensioner.

6.

Remove water pump mounting bolts and the water pump.

7.


> Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation

Catalytic Converter: Description and Operation

Fig. 32 Single & Twin Catalytic Converters

Fig. 32.

The catalytic converter is an emission control device added to the exhaust system to effectively reduce the levels of carbon monoxide andhydrocarbons entering the atmosphere. There are two types of catalytic converters used on these vehicles. The two types are, pellet type and monolithic type. The pellet type converter wasused on early models and incorporates palladium coated pellets to control emissions. On later models, the monolithic type converter is used. Thisconverter contains a honeycomb insert that is coated with palladium catalytic material,

> Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications

Exhaust Manifold: Specifications

Exhaust Manifold 11-14 ft.lb

> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >

Locations



> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Throttle Control Vacuum Motor <--> [Engine Speed Governor Control Module] >

Component Information > Locations


Under Center Of I/P

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >

Specifications


Switch Torque


> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair



1.


2.



3.


4.


> Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications

> Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > By Symptom for Air/Fuel Mixture: > 140884 > Jan > 84 > Propane Idle Set -

Procedure


Models


Subject


Index

FUEL

Date

January 17, 1984

No..

14-08-84

P-94-C




1.


2.


NOTE:


3.


4.


5.


6.


7.


> Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > By Symptom for Air/Fuel

Mixture: > 140884 > Jan > 84 > Propane Idle Set - Procedure > Page 586

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

8.


9.






D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 3

10.


FIGURE 2



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



FIGURE 4

11.





12.


13.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

14.


15.


16.

17.


18.


19.


20.





D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



> Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > All Technical Service Bulletins for Air/Fuel Mixture: > 140884 > Jan > 84 >

Propane Idle Set - Procedure


Models


Subject


Index

FUEL

Date

January 17, 1984

No..

14-08-84

P-94-C




1.


2.


NOTE:


3.


4.


5.


6.


7.


> Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > All Technical Service

Bulletins for Air/Fuel Mixture: > 140884 > Jan > 84 > Propane Idle Set - Procedure > Page 596

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

8.


9.






D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 3

10.


FIGURE 2



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



FIGURE 4

11.





12.


13.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

14.


15.


16.

17.


18.


19.


20.





D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



> Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > By Symptom: > 140884 > Jan > 84 > Propane Idle Set - Procedure


Models


Subject


Index

FUEL

Date

January 17, 1984

No..

14-08-84

P-94-C




1.


2.


NOTE:


3.


4.


5.


6.


7.


> Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > By Symptom: > 140884 > Jan > 84

> Propane Idle Set - Procedure > Page 609

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

8.


9.






D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 3

10.


FIGURE 2



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



FIGURE 4

11.





12.


13.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

14.


15.


16.

17.


18.


19.


20.





D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



> Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 142084 > May > 84 > Engine

Specifications - Manual Corrections


Models


Subject


Index

FUEL

Date

May 21, 1984

No..

14-20-84

P-2112-C



> Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for

Idle Speed: > 142084 > May > 84 > Engine Specifications - Manual Corrections > Page 619

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)





> Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 141984 > May > 84 > Carburetor - Idle

Speed Adjustment on A/C Install


Models


Subject


Index

FUEL

Date

May 7, 1984

No.

14-19-84




1.


FIGURE 1


Idle Speed: > 141984 > May > 84 > Carburetor - Idle Speed Adjustment on A/C Install > Page 624

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

2.


FIGURE 2

3.


4.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

FIGURE 2


FIGURE 1

6.


7.


8.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)


Example:

FIGURE 2


FIGURE 2



1.


2.


3.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

4.


FIGURE 2




> Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 140884 > Jan > 84 > Propane Idle Set -

Procedure


Models


Subject


Index

FUEL

Date

January 17, 1984

No..

14-08-84

P-94-C




1.


2.


NOTE:


3.


4.


5.


6.


7.



Idle Speed: > 140884 > Jan > 84 > Propane Idle Set - Procedure > Page 632

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

8.


9.






D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 3

10.


FIGURE 2



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



FIGURE 4

11.





12.


13.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

14.


15.


16.

17.


18.


19.


20.





D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



> Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > 142084 > May > 84 > Engine

Specifications - Manual Corrections


Models


Subject


Index

FUEL

Date

May 21, 1984

No..

14-20-84

P-2112-C



> Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle

Speed: > 142084 > May > 84 > Engine Specifications - Manual Corrections > Page 642

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)





> Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > 141984 > May > 84 > Carburetor - Idle

Speed Adjustment on A/C Install


Models


Subject


Index

FUEL

Date

May 7, 1984

No.

14-19-84




1.


FIGURE 1


Speed: > 141984 > May > 84 > Carburetor - Idle Speed Adjustment on A/C Install > Page 647

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

2.


FIGURE 2

3.


4.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

FIGURE 2


FIGURE 1

6.


7.


8.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)


Example:

FIGURE 2


FIGURE 2



1.


2.


3.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

4.


FIGURE 2




> Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 651

> Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications


> Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams



> Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams > Page 659

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

TIMING MARK 1981-85 5.2L & 5.9L

> Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Vacuum Advance Unit <--> [Distributor Advance Unit] > Component Information > Specifications > Electrical Specifications


> Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Vacuum Advance Unit <--> [Distributor Advance Unit] > Component Information > Specifications > Electrical Specifications >

Page 665

> Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 181788 > Oct > 88 > Spark Plugs - Oil Fouling/

Misfire on Hard Acceleration


Models


Subject


Index

FUEL

Date

October 17, 1988

No.

18-17-88


FIGURE 1

SYMPTOM/CONDITION



> Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2





FIGURE 1

DIAGNOSIS





PN MD009440

PN MD009786

1.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

2.



FIGURE 3

3.


a.

Remove spark plug.

b.



d.


e.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

4.


5.



> Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 181788 > Oct > 88 > Spark Plugs

- Oil Fouling/Misfire on Hard Acceleration


Models


Subject


Index

FUEL

Date

October 17, 1988

No.

18-17-88


FIGURE 1

SYMPTOM/CONDITION



> Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service

Bulletins for Spark Plug: > 181788 > Oct > 88 > Spark Plugs - Oil Fouling/Misfire on Hard Acceleration > Page 682

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2





FIGURE 1

DIAGNOSIS





PN MD009440

PN MD009786

1.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

2.



FIGURE 3

3.


a.

Remove spark plug.

b.



d.


e.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

4.


5.



> Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Page 685

> Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications


Pressure 170 psi

> Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications




Jet Valve

Exhaust 0.01 in

Intake 0.006 in

> Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 692






Fig. 12.




JET VALVE



Fig. 13.


> Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications


Switch Torque


> Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations



> Powertrain Management > Computers and Control Systems > Idle Up Control Valve > Component Information > Description and Operation

Idle Up Control Valve: Description and Operation

Fig. 19 Throttle opener system. 1982-86 models except 1982 Champ & Colt (federal) w/1400cc engine & manual transaxle

1982-88 Models exc. 1982 Champ & Colt (federal) w/1400cc engines & manual transaxle

Fig. 19,

This system, consists of a throttle opener assembly, a solenoid valve, an engine speed sensor and the air conditioning compressor switch. When the compressor is switched on, the speed sensor detects a drop in engine speed, and activates the solenoid valve. The solenoid valve thentransfers intake manifold vacuum to the throttle opener, which opens the throttle valve via the throttle opener lever. The engine speed, therefore, isbalanced against the air conditioning compressor load, resulting in improved idle and decreased levels of exhaust pollutants.

> Powertrain Management > Computers and Control Systems > Idle Up Control Valve > Component Information > Description and Operation > Page 703

Idle Up Control Valve: Adjustments


1.

Start engine and allow to reach normal operating temperature.

2.

Ensure that all electrical accessories are `Òff,'' then position transmission in ``Neutral.''

3.

Set curb idle to specifications.

4.

5.

With air conditioning system `Òff,'' disconnect vacuum hose from throttle opener nipple, then apply 20 inches Hg vacuum to throttle opener witha suitable vacuum pump.

Fig. 19, Adjust engine speed with throttle opener setting screw, to the following specifications: a. On 1982 Champ & Colt (1600cc engine), set engine speed to 900 50 RPM for automatic transaxle equipped vehicles, or 850 50 RPM for manual transaxle equipped vehicles. b. On 1982 Challenger, Sapporo & Pickup, set engine speed to 900 50 RPM.c. On 1983 Challenger & Sapporo, set engine speed to 1050 50 RPM.d. On 1983 Colt, set engine speed to 1100 50 RPM for manual transaxle equipped vehicles, or 1150 50 RPM for automatic transaxle equipped vehicles.

> Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions

Information Bus: Diagnostic Trouble Code Descriptions

For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes

> Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions > Page 708

Information Bus: Diagnostic Trouble Code Tests and Associated Procedures

For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes

> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations



> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications


Switch Torque


> Powertrain Management > Emission Control Systems > Secondary Air Supply <--> [Air Injection] > Air Diverter Valve > Component Information > Description and Operation

Air Switching Valve System 1982-84 Pickup w/2000cc & 2600cc engines

> Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation

Catalytic Converter: Description and Operation

Fig. 32 Single & Twin Catalytic Converters

Fig. 32.

The catalytic converter is an emission control device added to the exhaust system to effectively reduce the levels of carbon monoxide andhydrocarbons entering the atmosphere. There are two types of catalytic converters used on these vehicles. The two types are, pellet type and monolithic type. The pellet type converter wasused on early models and incorporates palladium coated pellets to control emissions. On later models, the monolithic type converter is used. Thisconverter contains a honeycomb insert that is coated with palladium catalytic material,

> Powertrain Management > Emission Control Systems > Slow Cut Solenoid Valve <--> [Deceleration Valve] > Component Information > Description and Operation

Slow Cut Solenoid Valve: Description and Operation

Fig. 16 Deceleration spark advance system

Fig. 19b Air Switching Valve System

> Powertrain Management > Emission Control Systems > Slow Cut Solenoid Valve <--> [Deceleration Valve] > Component Information > Description and Operation > Page

728

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

Fig. 18a Coasting Air Valve System

Fig. 18a. Fig. 19a.

Fig. 16,

Fig. 17.

Fig. 16.

The deceleration system used on some 1982-84 models includes a coasting air valve system, and an air switching valve system, Some 1981-88 models incorporate a deceleration spark advance system, and/or a dashpot, The coasting air valve system and air switching valve system are used to reduce HC emissions during deceleration. The engine speed sensor whichcontrols the solenoid valve, will prevent the coasting air valve or air switching valve from operating at or below a specified engine RPM by opening thesolenoid valve. On 1400, 1600 and 2,000 cc engines, the specified engine speed is 1800 RPM (+/- 200 RPM). On 2,600cc engines, the specified enginespeed is 1600 RPM (+/- 200 RPM). This is done to prevent poor idling or engine stalling at lower engine speeds. The coasting air valve suppliesadditional air to the intake manifold at engine speeds within the specified range, from a port located below the secondary throttle valve. The airswitching valve supplies additional air to the intake manifold at engine speeds within the specified range, from the idle mixture adjusting screw passagelocated below the primary throttle valve. The coasting air valve and air switching valve are built into the carburetor. The deceleration spark advance system consists of an engine speed sensor and a solenoid valve, During deceleration, ignition timing isadvanced by intake manifold vacuum acting upon the distributor vacuum advance unit diaphragm, which is routed through the solenoid valve. At orbelow a specified engine RPM, the engine speed sensor will activate the solenoid valve, changing vacuum acting upon the distributor vacuum advanceunit diaphragm from intake manifold vacuum to carburetor ported vacuum. On some models a dashpot is used to delay throttle valve closure during deceleration to its normal idle speed position to reduce HC emissions.

> Powertrain Management > Emission Control Systems > Slow Cut Solenoid Valve <--> [Deceleration Valve] > Component Information > Description and Operation > Page 729

Slow Cut Solenoid Valve: Adjustments

Top Of Engine

> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Evaporative Emission Control Canister

Evaporative Emission Control Canister: LocationsEvaporative Emission Control Canister

A sealed, maintenance free, charcoal canister is used on all engines and is located in the wheel well area of the engine compartment.

> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Evaporative Emission Control Canister > Page 735

Evaporative Emission Control Canister: LocationsCheck Valve

Top Of Fuel Tank

> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Locations

Liquid Vapor Separator: Locations

Top Of Fuel Tank

> Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations

EGR Valve: Locations

Top Of Engine

> Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation

Positive Crankcase Ventilation: Description and Operation

Positive Crankcase Ventilation (PCV) System. 1982-86 2600cc engine & 1982-86 2000cc engine

DESCRIPTION

Exc. 1983-85 Pickup w/ Diesel Engine

Fig. 2.

This system incorporates a PCV valve which is located at the rocker arm cover, With this system, fresh air is routed from the air cleaner tothe front of the valve cover and into the crankcase where the fresh air is mixed with the blow-by gasses. The mixture of fresh air and blow-bygasses then passes through the PCV valve and is drawn through a hose to the intake manifold and to the combustion chamber. Under high speed orduring acceleration conditions, the blow-by gasses are drawn through the PCV valve to the intake manifold and through the breather to the aircleaner and routed into the combustion chamber.

SYSTEM TESTING

Fig. 2.

1. Check if hoses or PCV valve is clogged.2. Check air flow through hoses as shown in

> Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation > Page 746

Positive Crankcase Ventilation: Testing and Inspection

Positive Crankcase Ventilation (PCV) System. 1982-86 2600cc engine & 1982-86 2000cc engine

DESCRIPTION

Exc. 1983-85 Pickup w/ Diesel Engine

Fig. 2.

This system incorporates a PCV valve which is located at the rocker arm cover, With this system, fresh air is routed from the air cleaner tothe front of the valve cover and into the crankcase where the fresh air is mixed with the blow-by gasses. The mixture of fresh air and blow-bygasses then passes through the PCV valve and is drawn through a hose to the intake manifold and to the combustion chamber. Under high speed orduring acceleration conditions, the blow-by gasses are drawn through the PCV valve to the intake manifold and through the breather to the aircleaner and routed into the combustion chamber.

SYSTEM TESTING

Fig. 2.

1. Check if hoses or PCV valve is clogged.2. Check air flow through hoses as shown in

> Powertrain Management > Emission Control Systems > Thermostatic Air Cleaner > Component Information > Description and Operation

Thermostatic Air Cleaner: Description and Operation

Fig. 3 Heated air intake (HAIS) system

DESCRIPTION

Exc. Diesel & Turbocharged Engines

Fig. 3,

84 F

84 F 113 F

113 F

In this system, the hot air control valve is controlled by a vacuum motor/temperature sensor combination system which responds to intakemanifold vacuum and temperature inside the air cleaner housing. When temperature inside air cleaner is below , air bleed valve remainsclosed, forcing intake manifold vacuum to be applied to diaphragm of vacuum motor which then opens air control valve and allows heated air toenter. If air cleaner temperature is between and , air flow will occur through both hot and cold air circuits. When air cleanertemperature is above , the air bleed valve is fully opened, causing air control valve to close fully regardless of intake manifold vacuum,thereby allowing only cold air to flow.

VACUUM SYSTEM TESTING

84 F

113 F 1. Check that heat cowl to air cleaner and all vacuum hoses are properly attached and in good condition.2. With cold engine and ambient temperature of less than , air control valve should be in up position.3. With engine warmed up and running, check temperature of air entering air cleaner. When air temperature exceeds , the air control valve should be in down position.

84 F 15 in.Hg (380 mmHg) 4. Remove air cleaner from engine and allow to cool down to under . Apply vacuum to sensor and check that valve is in up position. If valve does not rise, check vacuum motor for proper operation.

10 in.Hg (250 mmHg) 5. To test vacuum motor, apply of vacuum using tool C-4207 or equivalent. Valve should be in full up position. If vacuum motor fails to operate properly, replace air cleaner housing assembly.

> Powertrain Management > Emission Control Systems > Thermostatic Air Cleaner > Component Information > Description and Operation > Page 750

Thermostatic Air Cleaner: Testing and Inspection

Fig. 3 Heated air intake (HAIS) system

DESCRIPTION

Exc. Diesel & Turbocharged Engines

Fig. 3,

84 F

84 F and 113 F

113 F

In this system, the hot air control valve is controlled by a vacuum motor/temperature sensor combination system which responds to intakemanifold vacuum and temperature inside the air cleaner housing. When temperature inside air cleaner is below , air bleed valve remainsclosed, forcing intake manifold vacuum to be applied to diaphragm of vacuum motor which then opens air control valve and allows heated air toenter. If air cleaner temperature is between , air flow will occur through both hot and cold air circuits. When air cleanertemperature is above , the air bleed valve is fully opened, causing air control valve to close fully regardless of intake manifold vacuum,thereby allowing only cold air to flow.

VACUUM SYSTEM TESTING

84 F

113 F 1. Check that heat cowl to air cleaner and all vacuum hoses are properly attached and in good condition.2. With cold engine and ambient temperature of less than , air control valve should be in up position.3. With engine warmed up and running, check temperature of air entering air cleaner. When air temperature exceeds , the air control valve should be in down position.

84 F 15 in.Hg (380 mmHg) 4. Remove air cleaner from engine and allow to cool down to under . Apply vacuum to sensor and check that valve is in up position. If valve does not rise, check vacuum motor for proper operation.

10 in.Hg (250 mmHg) 5. To test vacuum motor, apply of vacuum using tool C-4207 or equivalent. Valve should be in full up position. If vacuum motor fails to operate properly, replace air cleaner housing assembly.

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications

> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > By Symptom: > 140884 > Jan > 84 > Propane Idle Set - Procedure


Models


Subject


Index

FUEL

Date

January 17, 1984

No..

14-08-84

P-94-C




1.


2.


NOTE:


3.


4.


5.


6.


7.


> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > By Symptom: > 140884 > Jan > 84 >

Propane Idle Set - Procedure > Page 763

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

8.


9.






D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 3

10.


FIGURE 2



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



FIGURE 4

11.





12.


13.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

14.


15.


16.

17.


18.


19.


20.





D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 142084 > May > 84 > Engine Specifications -

Manual Corrections


Models


Subject


Index

FUEL

Date

May 21, 1984

No..

14-20-84

P-2112-C



> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle

Speed: > 142084 > May > 84 > Engine Specifications - Manual Corrections > Page 773

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)





> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 141984 > May > 84 > Carburetor - Idle Speed



Models


Subject


Index

FUEL

Date

May 7, 1984

No.

14-19-84




1.


FIGURE 1



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

2.


FIGURE 2

3.


4.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

FIGURE 2


FIGURE 1

6.


7.


8.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)


Example:

FIGURE 2


FIGURE 2



1.


2.


3.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

4.


FIGURE 2




> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 140884 > Jan > 84 > Propane Idle Set -

Procedure


Models


Subject


Index

FUEL

Date

January 17, 1984

No..

14-08-84

P-94-C




1.


2.


NOTE:


3.


4.


5.


6.


7.



Speed: > 140884 > Jan > 84 > Propane Idle Set - Procedure > Page 786

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

8.


9.






D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 3

10.


FIGURE 2



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



FIGURE 4

11.





12.


13.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

14.


15.


16.

17.


18.


19.


20.





D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > 142084 > May > 84 > Engine Specifications -

Manual Corrections


Models


Subject


Index

FUEL

Date

May 21, 1984

No..

14-20-84

P-2112-C



> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: >

142084 > May > 84 > Engine Specifications - Manual Corrections > Page 796

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)





> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed: > 141984 > May > 84 > Carburetor - Idle Speed



Models


Subject


Index

FUEL

Date

May 7, 1984

No.

14-19-84




1.


FIGURE 1



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

2.


FIGURE 2

3.


4.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

FIGURE 2


FIGURE 1

6.


7.


8.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)


Example:

FIGURE 2


FIGURE 2



1.


2.


3.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

4.


FIGURE 2




> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Page 805

> Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > By Symptom for Air/Fuel Mixture: > 140884 > Jan > 84 > Propane Idle Set - Procedure


Models


Subject


Index

FUEL

Date

January 17, 1984

No..

14-08-84

P-94-C




1.


2.


NOTE:


3.


4.


5.


6.


7.


> Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > By Symptom for Air/Fuel Mixture: >


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

8.


9.






D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 3

10.


FIGURE 2



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



FIGURE 4

11.





12.


13.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

14.


15.


16.

17.


18.


19.


20.





D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



> Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > All Technical Service Bulletins for Air/Fuel Mixture: > 140884 > Jan > 84 > Propane Idle

Set - Procedure


Models


Subject


Index

FUEL

Date

January 17, 1984

No..

14-08-84

P-94-C




1.


2.


NOTE:


3.


4.


5.


6.


7.


> Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Technical Service Bulletins > All Technical Service Bulletins for Air

/Fuel Mixture: > 140884 > Jan > 84 > Propane Idle Set - Procedure > Page 824

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

8.


9.






D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 3

10.


FIGURE 2



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



FIGURE 4

11.





12.


13.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

14.


15.


16.

17.


18.


19.


20.





D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



> Powertrain Management > Fuel Delivery and Air Induction > Altitude Compensator > Component Information > Diagrams

High Altitude Compensator (HAC) system. 1983-86 Pickup w/2000cc 2000 & 2600cc engines; 1984 1400cc, 1600cc Non-turbocharged

> Powertrain Management > Fuel Delivery and Air Induction > Altitude Compensator > Component Information > Diagrams > Page 832

Altitude Compensator: Description and Operation

Fig. 24 High altitude compensation system.

Fig. 24,

HIGH ALTITUDE VEHICLE This system, is used to maintain the correct air/fuel mixture should the vehicle encounter atmospheric conditions normally present during highaltitude operation. A small bellows chamber, mounted in the engine compartment, is connected to the carburetor through hoses and is vented to atmosphere. Atmosphericpressure expands or contracts the bellows as necessary. A brass tapered seat valve is used to regulate the air flow accordingly. When a rarefied atmosphere is encountered, the air/fuel mixture becomes increasingly rich. At a pre-determined atmospheric pressure, the bellowsexpands, causing the tapered seat valve to lift off its seat and allow additional air to enter the main air bleeds. This additional air, when combined withthe air available, provides the system with the proper amount of air necessary to maintain the correct air/fuel mixture. When encountering differentaltitudes, the system provides varying amounts of air as needed. Once sufficient atmospheric pressure is restored, the tapered valve closes, enabling thesystem to return to its normal operational mode. Some models equipped with automatic transmission use a vacuum delay valve to delay the vacuum signal to the secondary throttle valve diaphragmchamber. This delay helps to decrease carbon monoxide and hydrocarbon emissions during vehicle acceleration.

> Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Jet > Component Information > Technical Service Bulletins > High Altitude Conversion Packages

Carburetor Jet: Technical Service BulletinsHigh Altitude Conversion Packages

Models

Subject

High Altitude Conversion Packages

Index

EMISSIONS

Date

April 9, 1984

No..

25-01-84

P-1423-CA package is now available to accommodate a customer who wishes to convert his 1984 low altitude emission package to the high altitude (over 4,000feet above sea level) emission package.

Vehicles with the low altitude package transferred to service in high altitude areas may exhibit undesirable driveability. However, the installation of ahigh altitude conversion package is voluntary and at the customer's expense.

The high altitude field conversion packages and procedures outlined below have been authorized in the following 1984 non-altitude equipped enginefamilies in service at altitudes above 4,000 feet above sea level.

CONVERSION INSTRUCTIONS

Sea Level to High Altitude

Altitude performance improvement adjustments for 1984 model year Ram-50 and Power Ram-50 trucks are as follows:

Gasoline Fueled Vehicles

1.

Advance basic timing as outlined below using the procedure in the 1984 Ram-50 service manual.

Engine Low Altitude High Altitude

2.0L

2.6 L (All)

5~ +/- 2~ BTDC

7~ +/- 2~ BTDC

10~ +/- 2~ BTDC

12~ +/- 2~ BTDC

2.

Remove air cleaner cover from the air cleaner assembly.

FIGURE 1

> Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Jet > Component Information > Technical Service Bulletins > High Altitude

Conversion Packages > Page 838

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

3.

Replace carburetor main (primary) air jet with jet supplied in the respective kit (Figure 1). Be sure to use the proper screwdriver (Figure 2).

4.

Reinstall air cleaner cover.

FIGURE 1

FIGURE 6

5.

Install emission control information update label supplied in kit (Figure 1) to properly cleaned location on the hood as indicated in Figure 6.

Performance Adjustments

The following procedure applies to vehicles returned to service at low altitude (below 4,000 feet above sea level) which previously had the high altitudekit installed. This procedure does not remove any components installed in high altitude kit.

1.

Remove complete air cleaner assembly from engine (cover and filter housing).



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 4

2.

Remove jet air bypass screw "B" and install screw "A" from low altitude kit PN MD080351 (Figure 4). Place screw "B" in owners manual packetin glove compartment for reinstallation if vehicle is returned to high altitude operation at a later date.

3.

Reinstall air cleaner assembly.

FIGURE 3

FIGURE 6

4.

Install low altitude emission control update label supplied in kit, PN MD080351, to properly cleaned location on the hood as indicated in Figure 6.



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

(Do not remove high altitude emission update label.)

5.

Check the ignition timing and curb idle RPM according to the specified timing and idle setting procedure per the 1984 D-50, Power Ram-50 Truckservice manual.

FIGURE 5

IMPORTANT:

SHOULD THE VEHICLE BE RETURNED TO SERVICE AT HIGH ALTITUDE (ABOVE 4,000 FEET ABOVE SEALEVEL), SCREW "A" SHOULD BE REMOVED AND SCREW "B" REINSTALLED AND THE LOW ALTITUDEEMISSION UPDATE LABEL SHOULD BE REMOVED.

Diesel Power Vehicles

Vehicles taken from low altitude service to high altitude service should have the injection timing advanced from 5~ +/- 2~ ATC to 3~ +/- 2~ ATC.

Use injection timing procedure outlined in 1984 Ram-50, Power Ram-50 service manual, publication #81-370-4009, pages 14-26 through 14-28.


> Powertrain Management > Fuel Delivery and Air Induction > Dashpot > Component Information > Locations

Dashpot: Locations

On Carburetor, Top Of Engine

Top Of Engine

> Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - Alcohol Fuel Recommendations

Fuel: Technical Service BulletinsFuel - Alcohol Fuel Recommendations

Models

All Gasoline Fueled

Subject

Alcohol Blend Fuels

Index

FUEL

Date

October 22, 1984 No..

14-52-84

P-4644-CThe increasing availability of gasolines containing alcohol has resulted in the need to provide additional information relative to driveability problems thatmay be experienced with the use of gasolines containing alcohol. Chrysler's 1984 and 1985 Owner's Manual statement on gasolines containing alcoholreads 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 thevehicle 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 volatilityof 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 thevehicle 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 ToolCatalog.

It is our recommendation that customers are made aware of the cautionary fuel statement in the Owner's Manual in order to avoid unnecessarydriveability 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 lawswhich 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 independentretailers, however, may occur and should be recognized.


> Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - Alcohol Fuel Recommendations > Page

848

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

ALCOHOL BLENDS: WHERE THE MAJORS STAND

COMPANY

Amoco

MARKET

Iowa, Eastern Nebraska, Southeastern South

Dakota and Kansas.

Arco

Ashland

About 1,400 branded jobber and dealer outlets in

New York and Pennsylvania; wholesales to small refiners, unbranded distributors; owns a 200 million gallon a year methanol plant.

Kentucky, Ohio, Michigan, Indiana, and Iowa; joint

Chevron

Conoco

BLEND

10% Ethanol

Oxinol: 4.75%

Methanol, 4.57%

Co-solvents

10% Ethanol venture partner in a 60 gallon a year ethanol plant at Southpoint, Ohio.

About 1,000 stations in Kentucky and Tennessee; 10% Ethanol

83% interest in a 21 million gallon a year Kentucky ethanol plant.

Wholesales ethanol at terminals in Missouri, 10% Ethanol

Exxon

Getty

Illinois, Nebraska, and Kansas. Jobbers sell blends in Nebraska and Iowa and the company sells blends through its subsidiary, Western Stores in Iowa.

None None

Three small regions in Omaha, Nebraska; 10% Ethanol

Gulf

Northeastern Iowa, and Western Kansas. Owns 100 million gallon a year methanol plant in Delaware (but not blending).

Last year considered owning part of an ethanol plant in North Carolina.

None

Marathon

Mobil

Phillips

Shell

None

None

Illinois, Indiana, Missouri, and Iowa.

None

Sohio

COMPANY

None

MARKET

Southland Markets ethanol blends in 14 states, primarily

California, Florida, Illinois, Indiana, Iowa,

Kansas, New Mexico, Ohio, Tennessee, and Utah. Testing oxinol in Houston.

Sun Test marketed oxinol at about 200 branded stations in Pennsylvania.

None

None

10% Ethanol

None

None

BLEND

10% Ethanol,

Oxinol

None

Tenneco

Texaco

Tennessee and Florida, owns a 135 million gallon a year methanol plant in Texas, but does not blend methanol.

10% Ethanol

Illinois, Indiana, Kentucky, Western Tennessee, 10% Ethanol and St. Louis. Owns 50% of 60 million gallon a year ethanol plant in Illinois.

None None Union

Sources: Information Resources, Inc., Washington, D.C.

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Control Solenoid > Component Information > Locations

Fuel Pressure Control Solenoid: Locations

Top Of Engine

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Shut-off Solenoid > Component Information > Locations

Fuel Shut-off Solenoid: Locations

Top Of Engine

> Powertrain Management > Fuel Delivery and Air Induction > Throttle Control Vacuum Motor <--> [Engine Speed Governor Control Module] > Component Information > Locations


Under Center Of I/P

> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control (Linkage) > Component Information > Adjustments

Idle Speed Control (Linkage): Adjustments


1.


2.


3.


4.

5.



> Powertrain Management > Fuel Delivery and Air Induction > Idle Up Control Valve > Component Information > Description and Operation

Idle Up Control Valve: Description and Operation


1982-88 Models exc. 1982 Champ & Colt (federal) w/1400cc engines & manual transaxle

Fig. 19,

This system, consists of a throttle opener assembly, a solenoid valve, an engine speed sensor and the air conditioning compressor switch. When the compressor is switched on, the speed sensor detects a drop in engine speed, and activates the solenoid valve. The solenoid valve thentransfers intake manifold vacuum to the throttle opener, which opens the throttle valve via the throttle opener lever. The engine speed, therefore, isbalanced against the air conditioning compressor load, resulting in improved idle and decreased levels of exhaust pollutants.

> Powertrain Management > Fuel Delivery and Air Induction > Idle Up Control Valve > Component Information > Description and Operation > Page 868

Idle Up Control Valve: Adjustments


1.


2.


3.


4.

5.



> Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Throttle Control Vacuum Motor <--> [Engine Speed Governor Control Module] > Component Information

> Locations


Under Center Of I/P

> Powertrain Management > Fuel Delivery and Air Induction > Rollover/Pressure Relief Valve <--> [Rollover Valve, Fuel Tank] > Component Information > Locations

Rollover/Pressure Relief Valve: Locations

Top Of Fuel Tank

> Powertrain Management > Ignition System > Firing Order > Component Information > Specifications


> Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams



> Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams > Page 884

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

TIMING MARK 1981-85 5.2L & 5.9L

> Powertrain Management > Ignition System > Distributor, Ignition > Vacuum Advance Unit <--> [Distributor Advance Unit] > Component Information > Specifications > Electrical Specifications


> Powertrain Management > Ignition System > Distributor, Ignition > Vacuum Advance Unit <--> [Distributor Advance Unit] > Component Information > Specifications > Electrical Specifications > Page 890

> Powertrain Management > Ignition System > Pick-Up Coil, Ignition > Component Information > Specifications

> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair



1.


2.



3.


4.


> Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 181788 > Oct > 88 > Spark Plugs - Oil Fouling/Misfire on Hard

Acceleration


Models


Subject


Index

FUEL

Date

October 17, 1988

No.

18-17-88


FIGURE 1

SYMPTOM/CONDITION



> Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 181788 > Oct > 88

> Spark Plugs - Oil Fouling/Misfire on Hard Acceleration > Page 906

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2





FIGURE 1

DIAGNOSIS





PN MD009440

PN MD009786

1.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

2.



FIGURE 3

3.


a.

Remove spark plug.

b.



d.


e.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

4.


5.



> Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 181788 > Oct > 88 > Spark Plugs - Oil Fouling/Misfire on

Hard Acceleration


Models


Subject


Index

FUEL

Date

October 17, 1988

No.

18-17-88


FIGURE 1

SYMPTOM/CONDITION



> Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: >


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2





FIGURE 1

DIAGNOSIS





PN MD009440

PN MD009786

1.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 2

2.



FIGURE 3

3.


a.

Remove spark plug.

b.



d.


e.




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

4.


5.



> Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Page 917

> Powertrain Management > Ignition System > Spark Control System <--> [Thermal Vacuum Valve, Vacuum/Dist. Advance] > Component Information > Description and Operation

Spark Control System: Description and Operation

Fig. 18 Idling Spark Advance System

Fig. 18,

The vacuum chamber used in this system, is of the dual diaphragm type. The main diaphragm uses ported vacuum in the conventional mannerto advance ignition timing. The sub-diaphragm, however, is actuated by manifold vacuum tapped below the throttle valve and provides additional timingadvance during periods of deceleration and idle. This additional timing advance results in decreased levels of hydrocarbons entering the atmosphere viathe exhaust system.

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Transmission Vent Assembly - Relocation

Case: Technical Service BulletinsTransmission Vent Assembly - Relocation

Models

1984 Power Ram 50 Four Wheel Drive Pick-Up

Subject

Revised Transmission/ Vent Assembly

Index

TRANSMISSION

Date

October 1, 1984

No.

21-05-84

P-4394-/ P-4394-C

The transmission vent assembly on the subject model vehicles has been changed. The new vent has been relocated rearward and higher on thetransmission adapter housing. Relocation of the vent helps prevent oil "weepage" out the vent during low temperature operation.

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Transmission Vent Assembly -

Relocation > Page 927

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

FIGURE 2

The location of the new vent assembly is shown in Figure1, as compared to the location of the old vent in Figure 2.

Install the vent with the index notch toward the front of the vehicle. The vent part numbers are:

Old New

MD712895

NOTE:

MD715206

THE VENTS ARE NOT INTERCHANGEABLE.


> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Automatic Transmission - New Fluid Type

Fluid - A/T: Technical Service BulletinsAutomatic 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-2131A new automatic transmission fluid Type 7176, (PN 4318077 - quart and 4318079 - 55 gallon) has been released for all vehicles equipped withautomatic 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 shudderand/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 toattempting any other repairs, especially if the fluid has been changed previously.


> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Transaxle/Transmission - Automatic

Fluid - A/T: SpecificationsTransaxle/Transmission - Automatic




> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Transaxle/Transmission - Automatic > Page 934

Fluid - A/T: SpecificationsInitial Refill Capacity




> Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Adjustments

Clutch Pedal Assembly: Adjustments

Fig. 1 Clutch pedal adjustment specifications

MODELS W/CABLE RELEASE SYSTEM

Fig. 2 Clutch pedal height & freeplay measurement

1. Measure clutch pedal height (A). If height is not within specifications, adjust with pedal stopper bolt. If pedal height is not within specifications on models without stopper bolt, check pedal stop and pedal support for damage and wear and repair as needed.

2. Measure clutch pedal freeplay (B). If freeplay is not within specifications, adjust as follows:

> Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Adjustments > Page 939

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

Fig. 3 Clutch cable adjustment a. Pull outer cable away from cable retainer at toe board and turn adjusting wheel until clearance (C), is 0.12-0.16 inch for Ram 50, 0.2-0.24

inch for Colt or 0-0.04 inch for Colt Vista.

b. Depress clutch pedal several times and recheck pedal freeplay.c. Repeat adjustment as needed until freeplay is within specifications.

Fig. 4 Clutch release point measurement

3. After adjusting pedal height and freeplay, measure height of clutch pedal from floorboard at clutch release point (D).4. If release point is less than value specified in chart, check clutch assembly and release mechanism and repair as needed.

Fig. 2 Clutch pedal height & freeplay measurement

> Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Adjustments > Page 940

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

MODELS W/HYDRAULIC RELEASE SYSTEM

1. Measure clutch pedal height (A).2. Check clutch pedal clevis pin play. It should be 0.04-0.12 inch, measured at pedal.3. If clutch pedal height is not within specifications, turn either the clutch switch or adjusting bolt to bring height within specifications. If clevis pin

Do not press pushrod intomaster cylinder when adjusting clevis pin clearance. play is not within specifications, adjust clutch master cylinder pushrod as necessary to bring play within specifications.

4. Check clutch pedal freeplay and clutch release point. If either dimension is not within specifications, hydraulic system requires bleeding or clutch is faulty.

> Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations



> Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Technical Service Bulletins > Clutch Splines & Pilot Bushing - Lubrication

Pilot Bearing: Technical Service BulletinsClutch Splines & Pilot Bushing - Lubrication

Models

AA, AB, AD, AG, AH, AJ, AK, AL, AN, AP, AQ, AS Bodies Through 1989

Subject

Clutch Splines/Pilot Bushing Lubrication

Index

CLUTCH

Date

January 16, 1989

No.

06-01-89

P-0046 (C06-01-9)BODY CODE LEGEND

AA - Spirit/Acclaim

AD - Dodge Ram Pickup/Ram Charger

AH - LeBaron/LeBaron GTS

AK - Aries/Reliant

AN - Dodge Dakota/Dakota Sport

AQ - Chrysler TC

AB - Dodge Ram Van/Wagon

AG - Daytona

AJ - LeBaron

AL - Omni/Horizon

AP - Shadow/Sundance

AS - Caravan/Voyager

This Technical Service Bulletin supersedes ALL previous Service Technical Publications through 1989 covering the lubrication of the clutch splines andpilot bushing. The procedures outlined in this bulletin apply to all domestic cars and trucks equipped with manual transmissions and transaxles.

SERVICE PROCEDURE

NOTE:

CLUTCH SPLINES

1.

Thoroughly clean the input shaft clutch splines and clutch disc splines, they must be free of any dirt or rust.

2.

Apply a light coat of wheel bearing grease PN 4318064 evenly to the entire length of the exposed input shaft splines. Be sure all excessivelubricant is removed.

NOTE:

THE USE OF ALTERNATIVE OIL BASED LUBRICANTS IS NOT RECOMMENDED AS THESE LUBRICANTS WILLEVENTUALLY DRY UP OR BURN OFF LEAVING ONLY A DRY RESIDUE.

REAR WHEEL DRIVE VEHICLES - PILOT BUSHING

1.

Thoroughly clean the pilot bearing journal at the end of the input shaft and the inside of the pilot bushing.

2.

Apply a light coat of multi-purpose grease PN 4318063 to the inside of the pilot bushing.

THIS PROCEDURE SHOULD BE PERFORMED ANYTIME THE TRANSMISSION/TRANSAXLE IS REMOVED FROM THEENGINE AND/OR CLUTCH SERVICE IS PERFORMED.

NOTE:

POLICY:

FAILURE TO PERFORM THIS PROCEDURE MAY RESULT IN ONE OR MORE OF THE FOLLOWINGSYMPTOMS/CONDITIONS - HIGH SHIFTING EFFORT INTO FIRST AND SECOND GEAR, GEAR CLASH INTOREVERSE AND LOW GEARS, PILOT BUSHING NOISE AND CLUTCH DRAG.

INFORMATION ONLY

> Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications

Pressure Plate: Specifications

> Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Adjustments

Carrier Bearings: Adjustments

Front Drive Axle

1. Press side bearing inner race on to differential unit using tool No. MB990802.2. Install side bearing adjusting shims at each side of differential, then position differential into differential carrier.

Fig. 21 Measuring clearance between differential carrier & side bearing adjusting shim. Front driving axle

3. Push differential carrier to one side and measure clearance between side bearing shim and differential carrier.4. Measure thickness of side bearing shims that were used when measuring clearance between side bearing shims and differential carrier.5. Select two pairs of shims with a thickness equal to those used during clearance measurement plus 1/2 the clearance measure plus 0.002 inch.

Fig. 22 Installing side bearing adjusting shims. Front driving axle

6. Install one pair of side bearing adjusting shim to each side of differential, and check to ensure that there is no clearance between shim and carrier.

Rear Drive Axle

5. Measure drive gear to drive pinion backlash using a dial indicator. Drive gear to drive pinion backlash should be 0.005-0.007 inch. If backlash is less than specified, loosen side bearing nut on rear side of drive gear, then tighten side bearing nut on tooth side an equal amount.

6. After adjustment, tighten each side bearing nut by 1/2 distance of two adjacent holes on side bearing nut.

> Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Adjustments > Page 956

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

Fig. 23 Lock plate installation

7. Ensure backlash is within specifications, then install a suitable lock plate and torque attaching bolt to 11 to 16 ft. lbs..

> Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications

Fluid - Differential: Specifications

GL-5* Limited-Slip ..................................................................................................................................................................................................................

GL-5 Other ...............................................................................................................................................................................................................................


1.1 Liters 2.3 Pints Above -10F (-23C), 90, 85-W-90, 80W-90; -30 to -10F (-34 to -23C), 80W, 80W-90; below -30F (-34C), 75W Front ................................................................................................................................................................................................

1.5 Liters 3.2 Pints Rear .................................................................................................................................................................................................

LIMITED-SLIP IDENTIFICATION:Lift rear of vehicle, turn one wheel and the other will turn in the same direction

> Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Adjustments

Pinion Bearing: Adjustments

Fig. 20 Measuring drive pinion bearing preload

1. The adjustment of the drive pinion bearing preload should be performed after the adjustment of the pinion height. Remove the end yoke and insert the bearing preload adjusting shim between the pinion spacer and the bearing, and torque the end yoke nut to 116-159 ft. lbs. on front drive axles.On rear drive axles, torque nut to 137 to 181 ft. lbs. Pinion bearing preload should be within specifications. In case of using a torque wrench, adaptthe socket (use 1/2" 3/8" adapter) to the box.

2. Remove the end yoke, apply a thin coat of grease to the outside of the oil seal, then drive it into the gear carrier. Subsequently apply grease required to the oil seal lip contact surface of the end yoke shaft. Insert the end yoke, then torque the end yoke nut to 116-159 ft. lbs. on front driveaxles. On rear drive axles, torque nut to 137 to 181 ft. lbs.

> Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments

Pinion Gear: Adjustments

1. Press front and rear bearing outer races into gear carrier using a press or a hammer and a suitable drift. Ensure outer race makes full contact with gear carrier and does not tilt during installation.

2. Attach spacer, washer and nut to tool No. MB990819 or equivalent, then install front and rear drive pinion bearings into gear carrier. Tighten nut on installation tool until front and rear bearing preload is 6-9 inch lbs. on 1984-85 models or 3.5-4.3 inch lbs on 1986-88 models, without oil seal.Apply a suitable lubricant to washer during installation.

Fig. 16 Installed position of tool for checking drive pinion height

3. Install drive pinion bearings and tools from kit C-4626, into gear carrier according to tool manufacturer's instructions. Gradually tighten tool adjusting nut, until front and rear bearing preload is 6-9 inch lbs. on 1984-85 models or 3.5-4.3 inch lbs on 1986-88 models.

Fig. 17 Positioning tool in side bearing seat

Fig. 18 Drive pinion height selective shim chart

4. On all models, mount tool MB990552 or equivalent, in gear carrier side bearing seat, then select a suitable shim from chart, which corresponds to clearance between tools C-4626 and MB990552 or equivalents on. When installing tool MB990552, ensure side bearing seat is clean and cut outportion of tool is positioned as shown.

> Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > Page 966

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

Fig. 19 Installing drive pinion rear bearing

5. Install selected shim between rear bearing and drive pinion, then press rear bearing onto drive pinion. If gear is to be replaced, install new shims of same thickness as shims used on drive pinion. In determining thickness of shim pack, the amount of shim pack compression and bearing wearshould be taken into account.

> Transmission and Drivetrain > Differential Assembly > Ring Gear <--> [Ring Gear, Differential] > Component Information > Adjustments

Ring Gear: Adjustments

Fig. 24 Measuring ring gear backlash

1. Install a dial indicator on the back of the ring gear, and measure the amount of runout. Runout should be less than 0.002 inch. If the ring gear indicates excessive runout over the limits, change the position of the assembly with the differential case and measure the runout again. If the runoutis still excessive, replace the ring gear or the differential case as necessary.

2. Measurement of backlash of the drive pinion against the ring gear should be measured at 4 points on the ring gear with the drive pinion fixed securely to its final position. Install a dial indicator to the ring gear tooth edges. Backlash should be within specifications.

3. If the measured backlash is greater than specified, shift shims in an appropriate thickness of the ring gear teeth side to the other side (back of the ring gear) to obtain the proper backlash.

4. If the measured backlash is smaller than specified, reverse shifting of shims stated above.

> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Constant Velocity Type Axle Shaft Assembly

Axle Shaft: Service and RepairConstant Velocity Type Axle Shaft Assembly

Removal & Installation

Fig. 6 Drive axle assembly exploded view

Do not allow caliper to 1. Remove wheel and brake caliper assembly, leaving brake hose connected, and hang caliper from body or suspension arm. hang by brake hose.

Support lower control arm with suitable jack prior to disconnecting ball joints from 2. Remove hub cover assembly, then remove snap ring from drive axle.3. Remove knuckle and front hub assembly as a unit. steering knuckle.

4. To remove left drive axle, slowly lower jack supporting control arm, then pull drive axle from differential carrier.5. To remove right drive axle, raise right lower control arm with jack and proceed as follows:

Do not remove lifting a. Remove upper mounting nuts from right shock absorber, then remove shock absorber from arm post of side frame. device from lower arm until shock absorber has been reconnected.

b. Remove four nuts connecting right drive axle to inner shaft assembly, then remove right drive axle.

> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Constant Velocity

Type Axle Shaft Assembly > Page 976

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

6. Remove inner shaft from differential shaft carrier assembly.7. Remove dust seal.8. Reverse procedure to install noting the following: a. Torque right drive axle to inner shaft assembly bolts to 37-43 ft. lbs.b. On 1984 models, tighten shock absorber upper mounting nut until protrusion of stud above bottom of nut is 0.8 inch. On 1985-88 models, tighten shock absorber upper mounting nut until protrusion of stud above top of nut is 0.5 inch for 1985 models or 0.27-0.31 inch for 1986Ram 50 4 X 4 and 1987-88 Ram Raider. On 1987-88 Ram 50 4 X 4, tighten nut to end of threads. On all models, install jam nut and torque to9-13 ft. lbs.

c. Mount knuckle and front hub assembly together and check drive axle endplay as follows: Install snap ring onto drive axle. Position dial indicator on end of drive axle and turn drive axle in axial direction. Drive axle endplay should be 0.008-0.020 inch. Install proper spacer tobring endplay into specification.

Disassembly

1. Remove boot bands from Birfield joint and double offset joint boots. Discard bands and replace with new bands at reassembly.2. Remove circlip from double offset joint outer race.3. Remove drive axle from double offset joint outer race.4. Clean grease from outer race, then remove balls from cage.5. Turn double offset joint cage 30 degrees from position at which balls were installed and push cage down toward Birfield joint until it is off inner race.

6. Remove inner race snap ring, inner race and cage from end of drive axle.7. Remove snap ring from drive axle, then remove double offset joint boot and Birfield boot. Tape end of drive axle so splines do not damage boots as they are removed.

Do not disassemble Birfield joint. 8. Remove dust cover. 9. Using suitable tool and press, remove bearing from inner shaft.

Inspection

1. Inspect outer race of double offset joint for excessive wear or damage.2. Inspect bearing for damage to races.3. Inspect drive axle and inner shaft for damage to splines.4. Inspect drive and inner shaft for bending or other damage.5. Inspect Birfield joint for damage to balls, water contamination, rust and other foreign material.6. Inspect dust cover for proper shape and damage.7. Inspect Birfield joint and double offset joint boots for deterioration, tears or cracks.8. Inspect double offset joint inner race, balls and cage for damage, wear or rust.

Assembly

1. Press dust cover onto inner shaft.2. Press inner bearing onto shaft using tool No. MD990560.3. Press dust covers onto Birfield joints and double offset joints.4. Apply grease to drive axle.

Fig. 7 Driveshaft boot and band identification

5. Install Birfield joint boot, all boot bands and double offset joint boot on drive axle and Birfield joint.6. Install double offset joint cage onto drive axle with smaller diameter end of cage toward Birfield joint. Install snap ring, inner race and circlip onto drive axle.

7. Apply grease to double offset joint inner race and cage, then fit balls into cage.8. Apply 2-3 ounces of grease to outer race, then install race on drive axle.



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

9. Apply 2-3 ounces of grease to outer race, then install circlip.

10. Apply as much grease as was removed from Birfield joint during inspection, then install boot. Birfield joint boot should measure 3 inches in length from outer band to inner band.

> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Constant Velocity Type Axle Shaft Assembly > Page 978

Axle Shaft: Service and RepairConventional Fixed/Floating Axle Shaft

Axle Assembly Removal and Installation

EXC. MODELS EQUIPPED WITH INDEPENDENT REAR SUSPENSION

1. Raise vehicle and support at frame. Support rear axle with a suitable jack.2. Remove wheels and propeller shaft. Place matching mark on propeller shaft flange yoke and companion yoke for reassembly.3. Disconnect brake hose from brake line.4. Disconnect parking brake cable from both wheels and remove the parking brake cable lever on axle housing.5. Remove shock absorbers.6. Remove coil springs (if so equipped) or leaf springs as outlined.7. If equipped with coil springs, remove lower control arm, assist link and upper control arm.8. Remove rear axle assembly from vehicle.9. Reverse procedure to install.

Axle Shaft Removal and Installation

REMOVAL

Fig. 1 Rear axle shaft assembly exploded view. Ram 50 & Ram Raider

1. Raise and support rear of vehicle, then remove rear wheel and brake drum.2. Disconnect rear parking brake cable at equalizer and remove cable retaining bolts and heat shields as needed.3. Disconnect brake tube from wheel cylinder and plug line and open fitting.4. Remove 4 nuts securing bearing case, then remove axle shaft, bearing case and brake backing plate as an assembly. Use suitable slide hammer, if necessary, to free assembly from axle housing.

5. Remove O-ring and shims for preloading bearing. Retain shims for reassembly.



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

Fig. 2 Axle shaft bearing locknut removal & installation. Ram 50 & Ram Raider

6. Disengage lock washer then remove locknut using tool No. MB990785.

Fig. 3 Rear axle shaft bearing case removal. Ram 50 & Ram Raider

7. Reinstall locknut on axle shaft approximately 3 turns, then install tool No. MB990787-A and washers. Turn nuts with equal pressure to ensure smooth removal of bearing and remove bearing case from shaft.

8. Using hammer and suitable drift, remove bearing outer race from bearing case.9. Remove inner axle shaft oil seal from housing using suitable puller, and drive outer seal from bearing housing.

INSTALLATION

1. Apply wheel bearing grease to outer surface of bearing outer race and to lip of outer oil seal, then drive them into bearing case.2. Place backing plate, bearing case and bearing over rear axle shaft, then apply bearing grease to bearing rollers and install bearing race.3. Install washer, lock washer and locknut. Torque locknut to 130 - 159 ft. lbs. (177 - 216 Nm) using tool No. MB990785, then bend tab on lock washer into groove on locknut. If lock washer does not engage with locknut, slightly retighten locknut.

4. Apply bearing grease to lip of inner oil seal and drive seal into rear axle housing using tool No. C-4572.5. Adjust axial play of rear axle shaft as follows: a. Remove any rust or old sealer from mating surface of bearing case and housing.



D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

Fig. 1 Rear axle shaft assembly exploded view. Ram 50 & Ram Raider b. Insert 1 mm shim and O-ring into left side of housing, and apply silicone rubber sealant to mating face of bearing case.c. Install left side axle shaft into left side housing and torque bearing case nuts to 36 - 43 ft. lbs. (49 - 59 Nm).d. Install right side axle shaft into right side housing, without shim or O-ring, and temporarily torque bearing case nuts to 0.4 ft. lbs. (.6 Nm).

Measure and record gap between bearing case and housing using feeler gauge.

e. Remove axle shaft from housing, then select a shim with thickness of measured gap of step "d" and a shim with thickness from 0.05 - 0.20

mm (0.002 - 0.007 inch). Insert selected shims and O-ring into housing and apply silicone sealer to mating face of bearing case.

f.

6. Connect brake tube to wheel cylinder and install rear brake drum and wheel.

Install right side axle shaft into right side housing and torque bearing case nuts to 36 - 43 ft. lbs. (49 - 59 Nm). Then, using a dial indicator,check axial play as shown. The axial play should be 0.002 - 0.007 inch (0.05 - 0.20 mm). If specified play is not obtained, change thicknessof selected shims and reassemble.

> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Adjustments



> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Removal




> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Removal > Page 986

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)












MANUAL LOCKING HUB




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



DISASSEMBLY



INSPECTION




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)




ASSEMBLY










D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

proper alignment.







lbs.


> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Rear Axle Shaft - Retaining Nut Lock Washers


Models


Subject


Index

REAR AXLE

Date

April 17, 1989

No.

03-01-89

(CO0-02-9)


BODY CODE LEGEND




> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Locking Hubs - Racheting Noise


Models


Subject


Index

FRONT AXLE

Date

November 19, 1984

No.






SYMPTOM RESOLUTION


free-wheeling hub.






CAUSE





> Transmission and Drivetrain > Flywheel > Component Information > Specifications

Flywheel: Specifications

Flywheel to Crankshaft 94-101 ft.lb

> Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Technical Service Bulletins > Transmission Vent Assembly - Relocation

Case: Technical Service BulletinsTransmission Vent Assembly - Relocation

Models

1984 Power Ram 50 Four Wheel Drive Pick-Up

Subject

Revised Transmission/ Vent Assembly

Index

TRANSMISSION

Date

October 1, 1984

No.

21-05-84

P-4394-/ P-4394-C

The transmission vent assembly on the subject model vehicles has been changed. The new vent has been relocated rearward and higher on thetransmission adapter housing. Relocation of the vent helps prevent oil "weepage" out the vent during low temperature operation.

> Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Technical Service Bulletins > Transmission Vent Assembly -

Relocation > Page 1009

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 1

FIGURE 2

The location of the new vent assembly is shown in Figure1, as compared to the location of the old vent in Figure 2.

Install the vent with the index notch toward the front of the vehicle. The vent part numbers are:

Old New

MD712895

NOTE:

MD715206

THE VENTS ARE NOT INTERCHANGEABLE.


> Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications

Fluid - M/T: Specifications


2.1 Liters 4.4 Pints Type......................................................................................................................................................................................................80W, 75W-85W 4-speed RWD...................................................................................................................................................................................

2.3 Liters 4.8 Pints 5-speed RWD...................................................................................................................................................................................

> Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Technical Service Bulletins > Clutch Splines & Pilot Bushing - Lubrication

Input Shaft: Technical Service BulletinsClutch Splines & Pilot Bushing - Lubrication

Models

AA, AB, AD, AG, AH, AJ, AK, AL, AN, AP, AQ, AS Bodies Through 1989

Subject

Clutch Splines/Pilot Bushing Lubrication

Index

CLUTCH

Date

January 16, 1989

No.

06-01-89

P-0046 (C06-01-9)BODY CODE LEGEND

AA - Spirit/Acclaim

AD - Dodge Ram Pickup/Ram Charger

AH - LeBaron/LeBaron GTS

AK - Aries/Reliant

AN - Dodge Dakota/Dakota Sport

AQ - Chrysler TC

AB - Dodge Ram Van/Wagon

AG - Daytona

AJ - LeBaron

AL - Omni/Horizon

AP - Shadow/Sundance

AS - Caravan/Voyager

This Technical Service Bulletin supersedes ALL previous Service Technical Publications through 1989 covering the lubrication of the clutch splines andpilot bushing. The procedures outlined in this bulletin apply to all domestic cars and trucks equipped with manual transmissions and transaxles.

SERVICE PROCEDURE

NOTE:

CLUTCH SPLINES

1.

Thoroughly clean the input shaft clutch splines and clutch disc splines, they must be free of any dirt or rust.

2.

Apply a light coat of wheel bearing grease PN 4318064 evenly to the entire length of the exposed input shaft splines. Be sure all excessivelubricant is removed.

NOTE:

THE USE OF ALTERNATIVE OIL BASED LUBRICANTS IS NOT RECOMMENDED AS THESE LUBRICANTS WILLEVENTUALLY DRY UP OR BURN OFF LEAVING ONLY A DRY RESIDUE.

REAR WHEEL DRIVE VEHICLES - PILOT BUSHING

1.

Thoroughly clean the pilot bearing journal at the end of the input shaft and the inside of the pilot bushing.

2.

Apply a light coat of multi-purpose grease PN 4318063 to the inside of the pilot bushing.

THIS PROCEDURE SHOULD BE PERFORMED ANYTIME THE TRANSMISSION/TRANSAXLE IS REMOVED FROM THEENGINE AND/OR CLUTCH SERVICE IS PERFORMED.

NOTE:

POLICY:

FAILURE TO PERFORM THIS PROCEDURE MAY RESULT IN ONE OR MORE OF THE FOLLOWINGSYMPTOMS/CONDITIONS - HIGH SHIFTING EFFORT INTO FIRST AND SECOND GEAR, GEAR CLASH INTOREVERSE AND LOW GEARS, PILOT BUSHING NOISE AND CLUTCH DRAG.

INFORMATION ONLY

> Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications

Fluid - Transfer Case: Specifications


2.2 Liters 4.6 Pints Type......................................................................................................................................................................................................80W, 75W-85W All models .......................................................................................................................................................................................

> Transmission and Drivetrain > Transfer Case > Shift Fork, Transfer Case > Component Information > Technical Service Bulletins > Transfer Case Shift Lever - Redesigned

Shift Fork: Technical Service BulletinsTransfer Case Shift Lever - Redesigned

Models

1984 Power Ram 50 4-Wheel Drive Equipped With KM145 & KM146 Transmissions

Subject

New Transfer Case Shift Lever, Lug & Shift Fork

Index

TRANSMISSION

Date

12/10/84

No.

21-16-84

P-5389C

FIGURE 1

FIGURE 2

Approximately early July, 1984 a new transfer case shift lever entered production on 4-wheel drive Power Ram 50 trucks (Figure 1). The new lever has a

> Transmission and Drivetrain > Transfer Case > Shift Fork, Transfer Case > Component Information > Technical Service Bulletins > Transfer Case Shift Lever - Redesigned

> Page 1025

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

larger nylon coated lower end where it engages the shift lug and fork. The lug and fork were also changed to accommodate the new lever (Figure 2).

NOTE:

THE NEW SHIFT LEVER, LUG, AND FORK CAN BE USED IN PRIOR MODELS ONLY AS AN ASSEMBLY. DO NOTMIX COMPONENT PARTS.

Part

Lever Assembly, Control

New PN

MD718050

Old PN

MD704221

Lug, Shift (2WD-4WD) MD716798 MD711153

Fork, Shift (High-Low)


MD716797 MD700702

> Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Technical Service Bulletins > Transfer Case Shift Lever - Redesigned

Shifter Transfer Case: Technical Service BulletinsTransfer Case Shift Lever - Redesigned

Models

1984 Power Ram 50 4-Wheel Drive Equipped With KM145 & KM146 Transmissions

Subject

New Transfer Case Shift Lever, Lug & Shift Fork

Index

TRANSMISSION

Date

12/10/84

No.

21-16-84

P-5389C

FIGURE 1

FIGURE 2

Approximately early July, 1984 a new transfer case shift lever entered production on 4-wheel drive Power Ram 50 trucks (Figure 1). The new lever has a

> Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Technical Service Bulletins > Transfer Case Shift Lever - Redesigned >

Page 1030

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

larger nylon coated lower end where it engages the shift lug and fork. The lug and fork were also changed to accommodate the new lever (Figure 2).

NOTE:

THE NEW SHIFT LEVER, LUG, AND FORK CAN BE USED IN PRIOR MODELS ONLY AS AN ASSEMBLY. DO NOTMIX COMPONENT PARTS.

Part

Lever Assembly, Control

New PN

MD718050

Old PN

MD704221

Lug, Shift (2WD-4WD) MD716798 MD711153

Fork, Shift (High-Low)


MD716797 MD700702

> Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Sliding Type Caliper

Brake Caliper: Service and RepairSliding Type Caliper

Fig. 7 Sliding type caliper exploded view. Front disc brake

CALIPER & BRAKE PAD REMOVAL

1.

Remove wheel, then retainer clip and stopper plug.

2.

Loosen caliper mounting and remove caliper.

3.

Remove anti-squeak shims, then brake pad from caliper support.

CALIPER SERVICE

1.

Remove brake pads as previously outlined.

2.

Remove hose clip from strut area and disconnect brake hose from caliper, then remove caliper.

3.

Keep fingersaway from piston area to prevent injury. Remove dust boot, then cover outer surface of caliper with cloth. Apply compressed air through brake hose fitting to remove piston.

4.

Remove piston seal taking care not to damage caliper cylinder.

5.

Clean all parts using brake fluid.

6.

Apply rubber grease to piston seal and install into caliper cylinder.

7.

Lubricate piston and piston bore with brake fluid, then insert piston into bore taking care not to twist seal.

8.

Apply RX-2 grease or equivalent to dust boot attaching groove in caliper, then insert dust boot.

9.

Install brake pad, then apply Plastilube #2 or equivalent grease to stopper plug and caliper sliding surface. Install caliper and retainer clip.

10.

Connect and tighten brake hose, then bleed brakes.

Fig. 8 Sliding caliper brake pad clip installation. Front disc brake

BRAKE PAD INSTALLATION

1.

Clean exposed part of piston, then push piston into original position using hammer handle. If piston is difficult to move, open bleeder screw andpiston will move easily. Be sure to bleed brakes.

> Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Sliding Type Caliper > Page 1037

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

2.

Apply Plastilube grease or equivalent to both faces of outer pad anti-squeak shim, then install both brake pads with anti-squeak shims into calipersupport. Install clip B and inner and outer clips in proper directions.

3.

Install caliper, then stopper plug and retainer clip.


Brake Caliper: Service and RepairTwo Piece Pin Type Caliper

Fig. 1 Two piece pin type caliper exploded view

BRAKE PAD REMOVAL

1.

Remove the wheel.

2.

Remove the protector, by prying up the edge of the clip at the center of the pad protector with a screwdriver.

3.

Holding the center of the M-clip with fingers, detach the M-clip from the pad and the ends from the retaining pins.

4.

Pull the retaining pins from the caliper assembly and remove the K-spring.

5.

Remove the brake pad assembly by holding the backing plate area of the pad with pliers.

CALIPER REMOVAL

1.

Remove the brake pads as outlined previously.

2.

Remove the brake hose clip from the strut area, then disconnect the brake hose from the caliper.

3.

Remove the caliper assembly by loosening torque plate and adapter mounting bolts.

CALIPER OVERHAUL

1.

Loosen caliper attaching bridge bolts and separate the outer caliper from the inner caliper.

2.

Do not apply high pressure suddenlysince the piston may cause personal injury. After the removal of the dust seal, remove the piston by applying compressed air at the brake hose fitting.

3.

Remove the piston seal, using care not to damage the cylinder.

4.

Clean all parts using clean brake fluid.

5.

Apply rubber grease to the piston seal and apply brake fluid to the cylinder bore. Insert the piston seal into the piston carefully to preventdistortion.

6.

7.

Whenever the torque plate has been removed from the inner caliper, it is necessary to clean the torque plate shaft and the shaft bore of the caliperand apply suitable grease to the rubber bushing, wiper seal inner surface and torque plate shaft before assembly. Apply sufficient grease to thethreaded portion of the torque plate shaft.

CALIPER INSTALLATION

1.

Install caliper on adapter.

2.

Torque the caliper assembly (torque plate) to the adapter bolts to 58-72 ft. lbs.

3.

Torque the brake hose to 9-12 ft. lbs.


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

Fig. 2 Brake pad installation. Two piece pin type caliper


1.

Spread the piston, using the special tool, Piston Spreader (C-3992) or equivalent, then insert the brake shoe through the shim.

2.

Install the K-spring and M-clip.

3.

Install the pad protector.

Fig. 3 Installing K-spring & M-clip. Two piece pin type caliper

> Brakes and Traction Control > Disc Brake System > Brake Disc <--> [Brake Rotor/Disc] > Component Information > Specifications

Brake Disc: Specifications

Front Nominal Thickness 0.79 in

Minimum Thickness 0.72 in

Runout (T.I.R.) 0.006 in

> Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications

Brake Drum: Specifications

2WD 4WD

Rear Inside Diameter 9.5 in 10.0 in

> Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 1047

Fig. 3 Rear Drum Brake Assembly Exploded View - Ram Raider & 1984-88 Ram 50

> Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Diagrams

Fig. 3 Rear Drum Brake Assembly Exploded View - Ram Raider & 1984-88 Ram 50

> Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Diagrams > Page 1051

Brake Shoe: Adjustments

These brakes are equipped with self adjusting mechanisms, therefore periodic adjustments are not necessary. If stopping power is insufficient, or if brakepedal travel is excessive, brakes should be cleaned and inspected, and the self-adjusting mechanisms should be checked.

After performing brake service, adjust brake shoes as follows:

1.

Ensure shoes are centered on backing plate and measure width of brake shoes using suitable caliper. On Colt Vista models, also measure insidediameter of brake drum.

2.

Adjust width of brake shoes to approximately 7.06 inches for Colt or 9.97 inches for Ram 50 and Ram Raider. On Colt Vista, adjust brake shoes toa width approximately 0.060 inch less than inside diameter of brake drum.

3.

Install brake drums and adjust parking brake as outlined.

4.

If shoeactuating lever is pulled by parking brake cable, self-adjusters will not operate. After adjusting parking brake, release parking brake lever and ensure that shoe actuating lever is not being pulled by parking brake cable.

> Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Sliding Type Caliper

Brake Caliper: Service and RepairSliding Type Caliper

Fig. 7 Sliding type caliper exploded view. Front disc brake

CALIPER & BRAKE PAD REMOVAL

1.

Remove wheel, then retainer clip and stopper plug.

2.

Loosen caliper mounting and remove caliper.

3.

Remove anti-squeak shims, then brake pad from caliper support.

CALIPER SERVICE

1.

Remove brake pads as previously outlined.

2.

Remove hose clip from strut area and disconnect brake hose from caliper, then remove caliper.

3.

Keep fingersaway from piston area to prevent injury. Remove dust boot, then cover outer surface of caliper with cloth. Apply compressed air through brake hose fitting to remove piston.

4.

Remove piston seal taking care not to damage caliper cylinder.

5.

Clean all parts using brake fluid.

6.

Apply rubber grease to piston seal and install into caliper cylinder.

7.

Lubricate piston and piston bore with brake fluid, then insert piston into bore taking care not to twist seal.

8.

Apply RX-2 grease or equivalent to dust boot attaching groove in caliper, then insert dust boot.

9.

Install brake pad, then apply Plastilube #2 or equivalent grease to stopper plug and caliper sliding surface. Install caliper and retainer clip.

10.

Connect and tighten brake hose, then bleed brakes.

Fig. 8 Sliding caliper brake pad clip installation. Front disc brake


1.

Clean exposed part of piston, then push piston into original position using hammer handle. If piston is difficult to move, open bleeder screw andpiston will move easily. Be sure to bleed brakes.

> Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Sliding Type Caliper > Page 1057

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

2.

Apply Plastilube grease or equivalent to both faces of outer pad anti-squeak shim, then install both brake pads with anti-squeak shims into calipersupport. Install clip B and inner and outer clips in proper directions.

3.

Install caliper, then stopper plug and retainer clip.


Brake Caliper: Service and RepairTwo Piece Pin Type Caliper

Fig. 1 Two piece pin type caliper exploded view

BRAKE PAD REMOVAL

1.

Remove the wheel.

2.

Remove the protector, by prying up the edge of the clip at the center of the pad protector with a screwdriver.

3.

Holding the center of the M-clip with fingers, detach the M-clip from the pad and the ends from the retaining pins.

4.

Pull the retaining pins from the caliper assembly and remove the K-spring.

5.

Remove the brake pad assembly by holding the backing plate area of the pad with pliers.

CALIPER REMOVAL

1.

Remove the brake pads as outlined previously.

2.

Remove the brake hose clip from the strut area, then disconnect the brake hose from the caliper.

3.

Remove the caliper assembly by loosening torque plate and adapter mounting bolts.

CALIPER OVERHAUL

1.

Loosen caliper attaching bridge bolts and separate the outer caliper from the inner caliper.

2.

Do not apply high pressure suddenlysince the piston may cause personal injury. After the removal of the dust seal, remove the piston by applying compressed air at the brake hose fitting.

3.

Remove the piston seal, using care not to damage the cylinder.

4.

Clean all parts using clean brake fluid.

5.

Apply rubber grease to the piston seal and apply brake fluid to the cylinder bore. Insert the piston seal into the piston carefully to preventdistortion.

6.

7.

Whenever the torque plate has been removed from the inner caliper, it is necessary to clean the torque plate shaft and the shaft bore of the caliperand apply suitable grease to the rubber bushing, wiper seal inner surface and torque plate shaft before assembly. Apply sufficient grease to thethreaded portion of the torque plate shaft.

CALIPER INSTALLATION

1.

Install caliper on adapter.

2.

Torque the caliper assembly (torque plate) to the adapter bolts to 58-72 ft. lbs.

3.

Torque the brake hose to 9-12 ft. lbs.


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

Fig. 2 Brake pad installation. Two piece pin type caliper


1.

Spread the piston, using the special tool, Piston Spreader (C-3992) or equivalent, then insert the brake shoe through the shim.

2.

Install the K-spring and M-clip.

3.

Install the pad protector.

Fig. 3 Installing K-spring & M-clip. Two piece pin type caliper

> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications

Brake Master Cylinder: Specifications

Cylinder Bore Diameter 0.87 in

> Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 1063

Brake Master Cylinder: Service and Repair

1.

Disconnect the brake tube from the master cylinder.

2.

On 1984 Colt Hatchback, disconnect level sensor electrical connector.

3.

On models equipped with manual brakes remove clevis pin connecting pushrod to brake pedal.

4.

Remove the attaching bolts from the toe-board or power brake assembly.

5.

Reverse procedure to install. Torque attaching bolts to 6-9 ft. lbs. Torque brake tube flare nut to 9.5-12 ft. lbs. If the car is equipped with powerbrakes, check clearance between the back of the master cylinder piston and the power brake pushrod. It should be 0 to 0.03 in. If clearance is notcorrect, adjust the length of the pushrod.

> Brakes and Traction Control > Parking Brake System > System Information > Adjustments

Parking Brake System: Adjustments

1.

Apply parking brake with a force of approximately 66 lbs. while counting number of clicks. Lever should pull out 16-17 notches.

2.

If pull stroke is not as specified, loosen cable adjuster to release parking brake cable then depress brake pedal several times to ensure shoe to drumclearance is properly maintained by self-adjusters.

3.

If adjusting nut istightened excessively, self-adjuster mechanism will be inoperative. Tighten adjusting nuts or turnbuckle until brake lever stroke is 16-17 notches with a pulling force of approximately 66 lbs.

4.

After adjustment, ensure that brake equalizer on 1984-86 2 wheel drive models is nearly parallel with centerline of vehicle. On 1984-86 4 wheeldrive models and all 1987 models, ensure equalizer and joint are at right angles to each other.

> Brakes and Traction Control > Power Booster <--> [Power Brake Assist] > Vacuum Brake Booster > Component Information > Service and Repair

Vacuum Brake Booster: Service and Repair

1.

Remove master cylinder as outlined previously.

2.

Disconnect vacuum hose from power brake unit.

3.

Remove pin connecting power brake rod with brake pedal.

4.

Remove power brake unit attaching nuts and the power brake unit.

5.


> Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations



> Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Service and Repair



1.


2.



3.


4.


> Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair


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2.


3.


4.


5.





> Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations




> Starting and Charging > Battery > Component Information > Technical Service Bulletins > Battery - Checking Procedure Revision

Battery: Technical Service BulletinsBattery - Checking Procedure Revision

Models

All MMC Vehicles

Subject

Battery Checking Procedures

Index

ELECTRICAL

Date

December 5, 1988

No.

08-10-88

P-4983

(C08-11)

SYMPTOM/CONDITION

The battery checking procedure has been revised for all MMC vehicles. The following procedure should be used when checking the condition of thebattery.


> Starting and Charging > Battery > Component Information > Technical Service Bulletins > Battery - Checking Procedure Revision > Page 1090

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

^ BATTERY TESTING PROCEDURE

> Starting and Charging > Battery > Component Information > Specifications > Electrical Specifications

Battery: Electrical Specifications

Canada, Standard Battery


BCI Group Number 24

Cranking Performance 500 A

Except Canada, Standard Battery


BCI Group Number 25


> Starting and Charging > Battery > Component Information > Specifications > Electrical Specifications > Page 1093

Battery: Mechanical Specifications



BCI Group Number 24




BCI Group Number 25


> Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Specifications

Generator: SpecificationsRated & Test Output

Rated & Test Output

Rated Output 45 A

Test Output 41 A at 3000 rpm

> Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Charging Voltage Test

Generator: Testing and InspectionCharging Voltage Test

Fig. 1 Alternator charging voltage test connection. Exc. Battery voltage sensing type alternator

Exc. Battery Voltage Sensing Type

1.

With ignition switch in the "Off" position, disconnect battery positive cable, then connect an ammeter between cable and battery positive post.

2.

Connect a voltmeter between alternator terminal L and ground. Ensure voltage reading is zero. If a reading or needle deflection is indicated on thevoltmeter, either the alternator or alternator wiring is defective.

3.

Place ignition switch in the "On" position, then note voltmeter reading. Voltmeter should indicate a reading considerably less than battery voltage.If reading indicates battery voltage, the alternator may be defective.

4.

Connect jumper cable between battery positive post and battery positive cable, then start engine. This will prevent starting current from beingapplied to ammeter.

5.

Remove jumper cable connected between battery positive post and cable, then increase engine speed to 2000 to 3000 RPM and note ammeterreading. If reading is 5 amps or less (10 amps or less for 1987-88 models), note voltage reading. If reading is above 5 amps (10 amps or less for1987-88 models), either continue to charge battery until reading drops to 5 amps or less (10 amps or less for 1987-88 models) or install a fullycharged battery. The charging current may also be limited by installing a {1/4} ohm resistor in series with the battery.

6.

Charging voltage should be as listed in the "Alternator and Regulator Specification Chart."

Fig. 2 Alternator charging voltage test connection. Battery voltage sensing type alternator

Battery Voltage Sensing Type

1.

With ignition switch in the "Off" position, disconnect battery ground cable and connect a digital voltmeter between alternator S terminal, andground.

2.

Disconnect alternator output wire from alternator B terminal, then connect a DC ammeter in series between the B terminal and the disconnectedoutput wire. Connect positive lead of ammeter to B terminal. Connect negative lead to the disconnected output wire.

3.

Set engine tachometer and reconnect battery ground cable.

4.

5.

Place ignition switch in the "On" position and note voltmeter. The reading should be equal battery voltage. If reading is 0, there is either an opencircuit in the wire between alternator S terminal and battery positive terminal or a blown fusible link.

Start engine, keeping all accessories and lights off. Run engine at a constant 2500 RPM and read voltmeter when alternator output current drops to10 amps or less. Voltage reading should be as listed in the "Alternator and Regulator Specification Chart."

> Starting and Charging > Charging System > Generator <--> [Alternator] > Component Information > Testing and Inspection > Charging Voltage Test > Page 1100

Generator: Testing and InspectionOutput Current Test

Fig. 3 Alternator output test connection

1.

With ignition switch in the "Off" position, disconnect battery cables.

2.

Disconnect wire from terminal B of alternator, then connect an ammeter between battery positive cable and alternator B terminal.

3.

Connect a voltmeter between B terminal and ground.

4.

Connect battery ground cable to battery ground post, then note voltmeter reading. The voltmeter should indicate battery voltage.

5.

Connect a tachometer to engine, then start engine and turn on lights.

6.

Operate engine at approximately 2500 RPM and note ammeter reading. After engine has been started, the ammeter reading will gradually decreaseas the battery approaches a fully charged condition. Read the ammeter indication at its maximum value while increasing engine RPM. Refer to "Alternator and Regulator Specification Chart."

> Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications

Voltage Regulator: SpecificationsSystem Operating Voltage

System Operating Voltage

Voltage Setting 14.1-14.7 V at 68 deg F

Note: At Test Temperature

> Starting and Charging > Starting System > Clutch Switch > Component Information > Locations



> Starting and Charging > Starting System > Ignition Switch > Component Information > Service and Repair



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2.



3.


4.


> Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Service and Repair


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> Starting and Charging > Starting System > Starter Motor > Component Information > Specifications

> Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 1117

Starter Motor: Service and Repair

1.

Disconnect battery ground cable and remove air cleaner, as needed, to gain access to starter.

2.

Disconnect starter wiring.

3.

Remove starter mounting bolts, then the starter. On truck models, brake pipes, steering joint or A/C lines may prevent lifting starter from enginecompartment. If so, remove splash shield and remove starter from under vehicle.

4.

Before mounting starter, clean the mating surfaces of starter and the engine.

5.

Install starter and tighten mounting bolts so the starter motor shaft is perfectly parallel with the central axis of the engine in all directions. Torquemounting bolts to 16-23 ft. lbs.

6.

Connect starter wiring and battery ground cable.

> Starting and Charging > Starting System > Starter Relay > Component Information > Locations




> Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions


Group Index




> Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1126




> Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions


Group Index




> Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1132




> Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Alignment - Caster Adjustment Manual Revision

Alignment: Technical Service BulletinsAlignment - Caster Adjustment Manual Revision

Models

All Ram 50 Two & Four Wheel Drive Vehicles

Subject

Caster Adjustment - Service Manual Revision

Index

FRONT SUSPENSION

Date

03/18/85

No..

02-07-85

P-887C

Caster Adjustment

This bulletin is issued to supplement the service manual information regarding caster adjustment for Ram 50 pick-up trucks.

Caster

Two Wheel Drive

Four Wheel Drive

Specifications

2-1/2~ +/- 1~

2~ +/- 1~

NOTE:

POLICY:

CASTER DIFFERENCE BETWEEN LEFT HAND AND RIGHT HAND SIDES SHOULD NOT EXCEED 1/2~.

Information only

> Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 1138

Alignment: Specifications

Caster Angle

4WD

+1 to +3 deg

Except 4WD

+1 1/2 to +3 1/2 deg

Desired Caster

Camber Angle

2 deg 2 1/2 deg

Front +1/2 to +1 1/2 deg +1/2 to +1 1/2 deg

1 deg

Desired Camber Angle Front ---

Rear 1 deg

---

Toe

Rear

Front .08-.35 in

Rear ---

---

.08 to .35 in

---

> Steering and Suspension > Alignment > System Information > Service and Repair > Camber

Alignment: Service and RepairCamber

FRONT

WITH TWO WHEEL DRIVE

1. Using tool No. MB990805 to hold upper arm shaft to crossmember bolt in position, remove nut from engine compartment side and adjust the number of shims between upper arm shaft and crossmember.

2. The normal shim pack thickness is 0.16 inch. A change of 0.024 inch in thickness of the shim pack will provide a change of approximately 2/15 degree in camber adjustment.

WITH FOUR WHEEL DRIVE

Adjust number of shims between upper arm shaft and arm post of side frame. The normal shim package thickness is 0.12 inch. A change of 0.039 inchin thickness of shim pack will provide a change of approximately 13 minutes in camber adjustment. Camber adjusting shims are available inthicknesses of 0.039 and 0.079 inch.

REAR

Rear camber is pre-set during vehicle assembly and cannot be adjusted. If camber is not within specifications, check for worn or damaged suspensioncomponent, and damaged or deformed floor pan or body and repair as needed.

> Steering and Suspension > Alignment > System Information > Service and Repair > Camber > Page 1141

Alignment: Service and RepairCaster

Fig. 2 Caster adjustment. Ram Raider & 1984-86 Ram 50

Caster is adjusted by turning the upper control arm shaft as follows:1. Remove upper control arm.2. Rotate upper control arm shaft to alter caster setting. One half turn of the upper control arm shaft will cause the upper arm shaft to move approximately 0.049 inch forward or rearward, resulting in approximately 17 minute (17/60) change in caster setting.

3. Reinstall control arm and recheck caster.4. Repeat adjustment until caster is within specifications. Maximum variation between left and right sides should be less than 1/2.


Alignment: Service and RepairPreliminary Inspection

1. Road test vehicle noting any abnormal steering or handling characteristics.2. Ensure tires are the proper type, correctly inflated and that tires on each axle are the same size.3. Inspect ball joints, suspension arms, bushings and tie rods, and repair or replace any component that is damaged or excessively worn.4. Ensure wheel runout is not excessive, and that wheel bearings are properly adjusted.5. Jounce vehicle several times to settle suspension.6. Place vehicle on suitable alignment rack following manufacturer's instructions. On Ram 50 and Ram Raider models, remove hub cap and cotter pin

(2WD) or free wheeling hub (4WD), and attach alignment gauges to wheel hub.

7. Check and correct alignment angles in the following sequence: Rear toe and camber, caster, front camber and front toe.8. Correct any angle that is not within specifications. If no adjustment is possible, check for damaged or worn suspension components and/or damaged or distorted chassis and correct as needed.


Alignment: Service and RepairToe Adjustment

FRONT

On Colt models, remove outer bellows clip from tie rod before adjusting toe. After completing adjustment, reinstall clamp.The amount of toe-in of the left front wheel is reduced by turning the tie rod turnbuckle toward the front of the car and the amount of toe-in on theright front wheel is reduced by turning it toward the rear of the the car. After adjustment, the difference in length between the two tie rods should notexceed 0.2 inch (5 mm).

REAR

Rear toe is pre-set during vehicle assembly and cannot be adjusted. If toe is not within specifications, check for worn or damaged suspensioncomponents, and damaged or deformed floor pan or body and repair as needed.

> Steering and Suspension > Steering > Ball Stud <--> [Front Steering Knuckle] > Component Information > Service and Repair

Ball Stud: Service and Repair

Fig. 1 Front suspension exploded view

1. Raise and support front of vehicle, and place suitable jack under lower control arm to relieve spring tension from knuckle.2. Remove hub assembly as outlined, then remove brake rotor dust cover.3. Remove cotter pin and retaining nut, then disconnect tie rod from knuckle using suitable puller.4. Remove cotter pins and nuts, disconnect upper and lower ball joints, then remove knuckle.5. Reverse procedure to install.

> Steering and Suspension > Steering > Steering Column > Component Information > Diagrams

Fig. 9 Exploded view of steering column assembly. 1984-86 Ram 50

> Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service

Steering Gear: Service and RepairManual Steering Gear Service

Fig. 1 Disassembled view of manual steering gear, except rack & pinion

Disassembly

Prior to disassembly, note starting torque required to rotate mainshaft.

1. Place alignment marks on pitman arm and mainshaft, then remove nut and pull pitman arm from shaft, using tool No. C3894A.2. Remove breather plug and allow lubricant to drain from steering gear.3. Remove upper cover attaching bolts, then loosen adjuster bolt locknut and back off adjusting bolt 2 to 3 turns.4. Place mainshaft and cross shaft in the straight ahead position, then using a soft faced mallet tap on bottom of cross shaft and remove cross shaft and upper cover as an assembly. When removing components, use care not to damage cross shaft oil seal.

Do not 5. Position upper cover in a soft jawed vise, then remove adjusting bolt and separate upper cover from cross shaft. Retain spacer for reassembly.6. Remove end cover and mainshaft adjusting shims, then remove mainshaft and bearings. Retain mainshaft adjusting shims for assembly. disassemble mainshaft or ball nut assembly.

7. Remove cross shaft and mainshaft oil seals from steering gear housing.

Inspection

1. Check cross shaft and mainshaft bearings for wear and damage and replace as necessary. If cross shaft bearing is found to be worn or damaged, replace cross shaft, bearing and steering gear housing as an assembly.

> Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Manual Steering Gear Service > Page 1155

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

2. Check ball nut and mainshaft for smooth operation. If operation is not smooth or excessive freeplay is indicated, replace mainshaft and ball nut as an assembly.

3. Check to ensure that hole in breather plug is not clogged. A needle may be used to clear breather plug passage.

Assembly & Adjustment

1. Apply grease to mainshaft and cross shaft oil seal lips, then install seals on steering gear housing.2. Position steering gear housing in soft jawed vise, then position mainshaft into housing.3. Install gasket, mainshaft shims (same as removed) and end cover onto steering gear housing. Torque end cover attaching bolts to 11-14 ft. lbs.

Apply suitable sealer to end cover gasket and cover attaching bolts.

4. Using an inch pound torque wrench and tool No. CT1108, check mainshaft preload. Mainshaft preload should be 3-4.8 inch pounds. If preload is less than specified, remove adjusting shims to increase preload. If preload is more than specified, add shims to reduce preload. Adjusting shims areavailable in thickness from 0.002-0.020 inch.

5. Install adjusting bolt and spacer into groove on upper end of cross shaft. Use spacers to adjust axial play to 0-.002 inch. Spacers are available in thickness of 0.077-0.083 inch.

6. Carefully insert cross shaft into gear housing, meshing ball nut rack with cross shaft gear. Before installing, apply a small amount of gear oil to ball nut, cross shaft and cross shaft gear. Also apply a small amount of grease to cross shaft seal before installing cross shaft.

7. Apply suitable sealer to upper cover attaching bolts, except the breather plug, then install upper cover and torque attaching bolts to 11-14 ft. lbs.8. Align marks on Pitman arm and mainshaft, then install Pitman arm and tighten retaining nut.9. Measure steering gear backlash as follows: a. Insert a small amount of gear oil into steering gear through breather plug.b. Tighten adjusting bolt until it contacts gear teeth.c. Cycle Pitman arm left and right several times to mesh gear teeth.

Fig. 2 Steering gear backlash measurement. Manual steering gear, except rack & pinion

10. After completing assembly, measure mainshaft preload. Mainshaft preload should be 5.6-7.4 inch pounds. If not within specifications, check cross shaft, cross shaft bearing and end cover for proper installation. Also check adjusting bolt for improper adjustment.

11. Fill steering gear housing with 0.19 quarts of gear oil.


Steering Gear: Service and RepairPower Steering Gear Service

Fig. 4 Power steering gear exploded view

Disassembly

1. Remove adjusting locknut, then side cover bolts and turn in adjusting bolt 2 or 3 turns.2. With gear in neutral (center) position, tap bottom of cross shaft with plastic hammer to remove shaft.3. Remove valve housing nut using tool No. MB990667 for large gear and No. MB990852 for small gear, then valve housing bolts. While holding rack piston to avoid rotation, remove valve housing and rack piston.


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

Fig. 5 Measurement of rack piston backlash

4. Secure valve housing in vise with dial indicator as shown, then move rack and piston up and down to check backlash between groove of rack piston and the balls. Backlash should be 0.0039 inch for large gear and 0.080 inch for small gear maximum. Measure backlash with piston fullytightened and loosened 2 turns. If backlash exceeds limit, replace ball screw unit and rack piston as an assembly.

Do not lose any of the 26 balls.

5. Remove rack piston from valve housing by turning counterclockwise.

Fig. 6 Removal of top cover

6. Remove top cover of valve housing using tool No. MB990853 for small gear or special spanner wrench as shown.

Fig. 7 Components of rack piston

7. Remove circulator holder, circulator, seal ring and O-ring from rack piston.8. Remove thrust unit, thrust needle roller bearing, seal rings and O-rings from input worm unit.9. To disassemble subassembly components, proceed as follows:

Do not lose any needle bearing rollers. a. Turn in adjusting bolt at tip of cross shaft and remove side cover. b. Remove adjusting bolt and plate, O-ring and needle bearing from side cover. Do not remove O-ring and sealing at rear of needle bearing if no oil leaks from thread of adjusting bolt. Also, do not remove bleeder plug unless necessary.

c. Remove seal ring and O-ring from valve housing.d. Remove ball bearing and oil seal from top cover.e. Remove snap ring at bottom of gearbox, then back-up ring and oil seal. Pull out seal housing.f.

10. To assemble subassembly components, proceed as follows. Replace O-rings, seal rings and oil seals whenever disassembled.

a. Apply thin coat of multi-purpose grease to bearing surface of needle bearing and install rollers into side cover, then apply grease to bottom of side cover.

b. Insert adjusting bolt and plate into "T" slot on top of cross shaft, and adjust play to 0-.002 inch by selecting proper adjusting plate. When installing adjusting plate, place chamfered portion of plate to contact surface of cross shaft.


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

c. Install O-ring into side cover.d. Align cross shaft with side cover and tighten with adjusting bolt, then tighten lock bolt temporarily.e. Apply thin coat of multipurpose grease to lip of oil seal and press into top cover, then press fit ball bearing.f.

Apply thin coat of ATF to O-ring and seal ring, then insert into seal housing. Install seal housing straight into gear box with O-ring sidepositioned near mainshaft.

g. Apply thin coat of multipurpose grease to lip of oil seal, then press into gear box using tool No. CT-1008. Install back-up ring and snap ring.

Assembly

Do not apply excessive force.

1. Apply thin coat of ATF to input worm unit O-rings and install O-rings and seal rings alternately onto worm unit. 2. Install thrust plate, thrust needle bearing and thrust plate to both ends of worm unit in that order, then apply thin coat of ATF to each.3. Install O-ring and seal ring into groove of valve housing and apply thin coat of ATF to each.

Fig. 8 Tightening of top cover

4. Install input worm unit into valve housing, then O-ring into top cover and top cover with bearing and oil seal onto valve housing. While turning worm unit, tighten by using spring scale and special spanner wrench as shown. Rotate worm unit to check for uniform movement.

5. Install valve housing nut and tighten temporarily using tool No. MB990667 for large gear and No. MB990852 for small gear. Do not allow top cover to rotate. The final tightening will occur during total starting torque measurement later in assembly procedure.

6. Measure starting torque by using tool No. CT-1108 and torque wrench while turning input worm unit, ensure preload is 3.5-6.9 in. lbs. If necessary, readjust by loosening valve housing nut as in steps 4-5.

7. Install O-ring and seal ring to rack piston and apply thin coat of ATF to each.8. Install rack piston into worm shaft until piston contacts worm shaft end, then insert 19 balls into groove through 2 openings on top of piston. Do not rotate worm unit and piston while inserting balls. Do not allow hole to offset or turn during insertion of balls so balls will not fall into wronggroove. After insertion of all balls, ensure balls reach approximately 0.080 inch for large gear, or 0.5 inch for small gear below end of piston.Excessive clearance is an indication that a ball has fallen into wrong groove. If so, remove rack piston and insert balls.

9. Insert 7 balls into rack piston circulator. Apply multipurpose grease to balls to prevent them from falling from circulator. Install circulator and holder into rack piston.

10. Secure gear box in vise, then install valve housing and rack piston assembly into gear box and torque bolts to 33-40 ft. lbs. After installation, rotate

Do not force rack piston into gearbox as seal ring may be damaged.

assembly to move rack piston to neutral (center) position.

11. Apply thin coat of ATF to teeth and shaft of rack piston and multipurpose grease to oil seal lip of gear box, then install cross shaft assembly into gearbox and torque side cover bolts to 33-40 ft. lbs.

Fig. 9 Measurement of total starting torque

12. Measure total starting torque of input worm shaft at neutral (center) position using tool No. CT-1108 and adjust to 3.6-7.1 in. lbs. for large gear or

4.3-7.8 in. lbs. for small gear by turning adjusting bolt. Torque valve housing nut to 130-166 ft. lbs. using tool No. MB990667 for large gear or


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

No. MB990852 for small gear. Check input worm shaft for smooth rotation throughout its operation range.

Fig. 10 Installation position of Pitman arm

13. Align slit of cross shaft with marking of pitman arm and install pitman arm, then torque nut to 94-108 ft. lbs. Check clearance between center of gearbox bolt and pitman arm. Clearance should be 0.77 inch.


Steering Gear: Service and RepairSteering Gear Replacement

Manual Steering Gear Replacement

1. Disconnect steering shaft from steering gear main shaft.2. Disconnect tie rod from relay rod and pitman arm from relay rod using tool No. C3894A.3. Remove air cleaner and disconnect pressure and return hose from steering gear. Remove under cover.4. Remove starter from transmission.5. Remove steering gear. Use tool No. CT1106 if pitman arm is removed.6. Reverse procedure to install. Torque pressure hose to 40-47 ft. lbs., return hose to 29-36 ft. lbs., tie rod socket and relay rod connection to 26-32 ft. lbs. and steering gear to 40-47 ft. lbs.

7. Remove the clamp bolt connecting the steering shaft with the steering gear housing mainshaft.8. Using Pitman and idler arm puller (C-3894), disconnect the pitman arm and the relay rod.9. Remove the steering gear assembly from the body frame.10. Using the pitman arm puller (Special Tool CT-1106), remove the pitman arm from the cross shaft.11. Reverse procedure to install.

Power Steering Gear Replacement

1. Disconnect steering shaft from steering gear main shaft.2. Disconnect tie rod from relay rod and pitman arm from relay rod using tool No. C3894A.3. Remove air cleaner and disconnect pressure and return hose from steering gear. Remove under cover.4. Remove starter from transmission.5. Remove steering gear. Use tool No. CT1106 if pitman arm is removed.6. Reverse procedure to install. Torque pressure hose to 40-47 ft. lbs., return hose to 29-36 ft. lbs., tie rod socket and relay rod connection to 26-32 ft. lbs. and steering gear to 40-47 ft. lbs.

7. Disconnect steering shaft from steering gear mainshaft.8. Remove retaining nuts, then disconnect tie rod from relay rod and pitman arm from relay rod using puller C-3894A.9. Disconnect pressure and return hoses from steering gear, then remove steering gear mounting bolts and steering gear. On Pickup models with automatic transmission, it may be necessary to disconnect throttle linkage and remove splash shield. On Pickup models with manual transmission,it may be necessary to remove starter motor to permit steering gear removal.

10. Reverse procedure to install.

> Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Replacement

Ball Joint: Service and RepairLower Ball Joint Replacement

UPPER BALL JOINT

Ram 50 4 X 2

1. Remove upper control arm.2. Remove snap ring and dust cover from ball joint, then using tools Nos. MB990799 and MB990800, press ball joint from arm.3. Using a torque wrench, check torque required to start upper ball joint in motion. The torque required should be 0.6-2.5 ft. lbs. Inspect ball joint cover for wear and damage.

4. If ball joint is to be reused, lubricate with grease.5. Align ball joint and control alignment marks, then press ball joint into control arm using tools Nos. MB990799 and MB990800. The initial

If standard pressure is not obtained when pressing in balljoint, replace ball joint and/or control arm as necessary. pressure to install the ball joint to a depth of 0.12-0.24 inch is 1550 lbs. or above.

6. Using snap ring pliers, position snap ring into groove on ball joint case.7. Install dust cover and ring into groove on ball joint.8. Install upper control arm as outlined.

Ram 4 X 4

The following procedures are given for control arms removed from vehicle.

1. Remove rebound stop. Remove ring, dust cover and snap ring from upper ball joint.2. Remove upper ball joint using tool Nos. MB990799 and MB990800.3. Reverse procedure to install. Align ball joint and control alignment marks and press ball into upper arm using tool Nos. MB990799 and

MB990800. Initial pressure to install ball joint to a depth of 0.12-0.24 inch is 1500 lbs. minimum. If minimum ball joint pressure is not obtainedwhen pressing in ball joint, replace ball joint or upper arm as necessary.

LOWER BALL JOINT

Ram 50 4 X 2

1. Remove lower control arm as outlined.2. Remove snap ring and dust cover from ball joint.3. Remove ball joint to lower control arm attaching bolts, then remove ball joint.4. Check ball joint for axial play. Ball joint axial play should not exceed 0.02 inch.5. Lubricate ball joint with grease, then install ball joint dust cover and snap ring.6. Position ball joint on lower control arm, then install attaching bolts and torque to 22-30 ft. lbs.7. Install lower control arm as outlined.

Ram 4 X 4


1. Remove four lower ball joint retaining nuts and remove lower ball joint.2. Reverse procedure to install. Torque lower ball joint to lower arm nuts to 40-54 ft. lbs.

> Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Replacement > Page 1166

Ball Joint: Service and RepairUpper Ball Joint Replacement

UPPER BALL JOINT

Ram 50 4 X 2

1. Remove upper control arm.2. Remove snap ring and dust cover from ball joint, then using tools Nos. MB990799 and MB990800, press ball joint from arm.3. Using a torque wrench, check torque required to start upper ball joint in motion. The torque required should be 0.6-2.5 ft. lbs. Inspect ball joint cover for wear and damage.

4. If ball joint is to be reused, lubricate with grease.5. Align ball joint and control alignment marks, then press ball joint into control arm using tools Nos. MB990799 and MB990800. The initial

If standard pressure is not obtained when pressing in balljoint, replace ball joint and/or control arm as necessary. pressure to install the ball joint to a depth of 0.12-0.24 inch is 1550 lbs. or above.

6. Using snap ring pliers, position snap ring into groove on ball joint case.7. Install dust cover and ring into groove on ball joint.8. Install upper control arm as outlined.

Ram 4 X 4


1. Remove rebound stop. Remove ring, dust cover and snap ring from upper ball joint.2. Remove upper ball joint using tool Nos. MB990799 and MB990800.3. Reverse procedure to install. Align ball joint and control alignment marks and press ball into upper arm using tool Nos. MB990799 and

MB990800. Initial pressure to install ball joint to a depth of 0.12-0.24 inch is 1500 lbs. minimum. If minimum ball joint pressure is not obtainedwhen pressing in ball joint, replace ball joint or upper arm as necessary.

LOWER BALL JOINT

Ram 50 4 X 2

1. Remove lower control arm as outlined.2. Remove snap ring and dust cover from ball joint.3. Remove ball joint to lower control arm attaching bolts, then remove ball joint.4. Check ball joint for axial play. Ball joint axial play should not exceed 0.02 inch.5. Lubricate ball joint with grease, then install ball joint dust cover and snap ring.6. Position ball joint on lower control arm, then install attaching bolts and torque to 22-30 ft. lbs.7. Install lower control arm as outlined.

Ram 4 X 4


1. Remove four lower ball joint retaining nuts and remove lower ball joint.2. Reverse procedure to install. Torque lower ball joint to lower arm nuts to 40-54 ft. lbs.

> Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair

Control Arm: Service and Repair


> Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Page 1170

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

Fig. 4 Front suspension. Ram 50 4 X 2

1. Remove front wheel, brake caliper assembly and front hub assembly.2. Remove dust covers from anchor arm assemblies.3. Place alignment mark on torsion bar with mark on anchor arm B.4. Remove anchor arm assembly, then remove torsion bar from anchor arm assembly B.5. Remove stabilizer bar from lower arm, then remove shock absorber.6. Remove cotter pins and nuts from upper and lower ball joint studs at tie rod end.7. Disconnect tie rod from knuckle using tool C3894-A.8. Separate upper ball joint from knuckle using tool No. MB990635.


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

9. Separate upper ball joint from knuckle using tool No. C3894-A.

10. Remove bolts connecting upper arm shaft to arm post of side frame, then remove upper arm assembly.11. Remove two bolts attaching lower arm then remove lower arm.12. Reverse procedure to install, noting the following: a. Refer to torque specifications.b. Torque shock absorber lower mounting bolts to 6 to 8 ft. lbs. On 1984 models, tighten shock absorber upper mounting nut until protrusion of stud above bottom of nut is 0.8 inch. On 1985-88 models, tighten shock absorber upper mounting nut until protrusion of stud above top of nutis 0.5 inch for 1985 models or 0.27-0.31 inch for 1986 Ram 50 and 1987-88 Ram Raider. On 1987-88 Ram 50, tighten nut to end of threads.On all models, install jam nut and torque to 9-13 ft. lbs.

Fig. 2 Torsion bar anchor bolt installation. Ram 50 4 X 4, Ram Raider similar c. Refer to image and check dimension A when torsion bar and anchor arm are assembled. Standard value is 5.6-5.8 inch for left side and

5.4-5.6 inch for right side on Ram 50, or 5.32-5.64 inches for left side and 4.9-5.2 inches for right side on Ram Raider.

Fig. 3 Torsion bar anchor bolt specifications. Ram Raider d. Torque anchor bolt until protrusion is to specification shown for Ram 50 or for Ram Raider.e. On 1984 models, tighten stabilizer bar to lower arm nut until protrusion of stud above bottom of nut is 0.63-0.71 inch. On 1985-88 models, tighten stabilizer bar to lower arm nut until protrusion of stud above top of nut is 0.24-0.31 inch.

Fig. 4 Dimension between bump stop and bump stop bracket


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

f.

With installation procedure complete and vehicle lowered to ground, torque lower arm to bracket of side frame to 102-115 ft. lbs. Measuredistance A. Measured distance should be 2.8 inch. If measurement is out of specification, turn adjusting nut of torsion bar anchor bolt untilmeasurement comes into specification.

> Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair

Cross-Member: Service and Repair

Fig. 5 Location front suspension crossmember bolts

1. Install suitable jack under differential carrier.2. Remove front suspension crossmember from differential carrier assembly and from support bracket of side frame.3. Reverse procedure to install. Torque front suspension crossmember to support bracket of side frame bolt to 73-86 ft. lbs. Torque front suspension crossmember to bracket bolt to 22-30 ft. lbs.

> Steering and Suspension > Suspension > Ball Stud <--> [Front Steering Knuckle] > Component Information > Service and Repair

Ball Stud: Service and Repair


1. Raise and support front of vehicle, and place suitable jack under lower control arm to relieve spring tension from knuckle.2. Remove hub assembly as outlined, then remove brake rotor dust cover.3. Remove cotter pin and retaining nut, then disconnect tie rod from knuckle using suitable puller.4. Remove cotter pins and nuts, disconnect upper and lower ball joints, then remove knuckle.5. Reverse procedure to install.

> Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front

Stabilizer Bar: Service and RepairFront

Fig. 8 Positioning strut bar bushing retaining nuts (Typical)

RAM 50 4 X 2

1. Raise and support front of vehicle, then remove wheel and tire assembly.2. Disconnect stabilizer bar and strut bar from lower control arm.3. Remove strut bar bracket to body attaching bolts, then remove stabilizer bar and strut bar from strut bar bracket. When removing strut bar bushings note position and direction of bushings and washers for reassembly.

4. Reverse procedure to install, noting the following: a. When assembling strut bar to bracket and set clearance between end of strut bar and retaining nut. Clearance should be 3.8 inches for 1984

Ram 50 4 X 2 or 2.9 inches for 1985-88 Ram 50 4 X 2.

b. After installing strut bar bushings, temporarily tighten outer retaining nut, as nut will be tightened to specified torque after vehicle has been lowered.

c. When connecting stabilizer bar to lower control arm, set clearance between end of bolt and retaining nut to 0.87-0.94 inch for Ram 50 4 X 2.d. Tighten components to the following torque: Stabilizer bar bracket bolts, 6-8 ft. lbs. Stabilizer bar to lower control arm: Ram 50 4 X 2, 18-25 ft. lbs. Strut bar to bracket nuts, 54-61 ft. lbs. Strut bar to lower control arm: Ram 50 4 X 2, 51-61 ft. lbs. Strut bar bracket to frame, 25-33 ft.lbs.

> Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front > Page 1183

Stabilizer Bar: Service and RepairRear

1. Remove stabilizer bar from stabilizer link assembly and lower arm.2. Reverse procedure to install, noting the following: a. On 1984 models tighten stabilizer link to No. 1 crossmember until protrusion of stud above bottom of nut is 0.63-0.71 inch. b. On 1984 models, tighten stabilizer bar to lower arm nut until protrusion of stud above bottom of nut is 0.63-0.71 inch.

> Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Coil Spring Replace

Suspension Spring ( Coil / Leaf ): Service and RepairFront Coil Spring Replace

Fig. 7 Separating upper & lower ball joints from steering knuckle. Ram 50 4 X 2

RAM 50 4 X 2

1. Remove wheel and tire assembly, then remove caliper and rotor.2. Loosen nut at end of strut bar, then disconnect strut bar and stabilizer bar from lower control arm.3. Remove shock absorber, then install suitable spring compressor and compress coil spring.4. Remove cotter pin and nut from lower control arm, then using tool No. C-3564A, separate lower ball joint from steering knuckle.5. Carefully loosen spring compressor and remove coil spring.6. Reverse procedure to install. Torque lower ball joint nut to 87-130 ft. lbs., then install cotter pin. Torque brake strut bar nut to 54-61 ft. lbs. and strut bar to lower control arm attaching bolts to 51-61 ft. lbs. Torque stabilizer bar bolts to 18-5 ft. lbs.

> Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Coil Spring Replace > Page 1188

Suspension Spring ( Coil / Leaf ): Service and RepairLeaf Spring Replacement

Fig. 10 Leaf spring rear suspension. Ram 50 & Ram Raider

1. Raise rear of vehicle and position jackstands under frame side rails, then remove wheel and tire assembly. Lower jack and allow vehicle to rest on jackstands.

2. Disconnect parking brake cable bracket from leaf spring.3. Disconnect shock absorber from upper and lower mounting.4. Loosen U-bolt nuts, then raise rear axle housing until axle clears U-bolt seat, and remove U-bolt seat.5. Remove spring pin from spring front mounting and shackle pin from spring rear mounting, then remove leaf spring assembly.

> Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front

Suspension Strut / Shock Absorber: Service and RepairFront

RAM 50 4 X 2

Disconnect shock absorber at upper and lower mountings, then remove shock absorber from vehicle. When installing, torque shock absorber upperattaching bolts to 9-13 ft. lbs. and lower attaching bolts to 6-9 ft. lbs.

RAM 50 4 X 4

1. Detach shock absorber from upper and lower mounting, then remove shock absorber.2. Reverse procedure to install. Torque shock absorber lower mounting bolts to 6 to 8 ft. lbs. On 1984 models, tighten shock absorber upper mounting nut until protrusion of stud above bottom of nut is 0.8 inch. On 1985-88 models, tighten shock absorber upper mounting nut untilprotrusion of stud above top of nut is 0.5 inch for 1985 models or 0.27-0.31 inch for 1986 Ram 50 4 X 4 and 1987-88 Ram Raider. On 1987-88Ram 50 4 X 4, tighten nut to end of threads. On all models, install jam nut and torque to 9-13 ft. lbs.

> Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 1193

Suspension Strut / Shock Absorber: Service and RepairRear

Fig. 10 Leaf spring rear suspension. Ram 50 & Ram Raider

1. Raise rear of vehicle and position jackstands under frame side sills.2. Remove wheel and tire assembly, then disconnect shock absorber at upper and lower mounting and remove from vehicle.3. Reverse procedure to install. Torque upper and lower mounting nuts to 13-18 ft. lbs.

> Steering and Suspension > Suspension > Wheel Bearing > Component Information > Adjustments



> Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Removal




> Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Removal > Page 1199

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)












MANUAL LOCKING HUB




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



DISASSEMBLY



INSPECTION




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)




ASSEMBLY










D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

proper alignment.







lbs.


> Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Rear Axle Shaft - Retaining Nut Lock Washers


Models


Subject


Index

REAR AXLE

Date

April 17, 1989

No.

03-01-89

(CO0-02-9)


BODY CODE LEGEND




> Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Locking Hubs - Racheting Noise


Models


Subject


Index

FRONT AXLE

Date

November 19, 1984

No.






SYMPTOM RESOLUTION


free-wheeling hub.






CAUSE





> Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Adjustments



> Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Removal




> Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Removal > Page 1220

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)












MANUAL LOCKING HUB




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)



DISASSEMBLY



INSPECTION




D50/Ram 50 L4-1997cc 2.0L SOHC (1984)




ASSEMBLY










D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

proper alignment.







lbs.


> Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Rear Axle Shaft - Retaining Nut Lock Washers


Models


Subject


Index

REAR AXLE

Date

April 17, 1989

No.

03-01-89

(CO0-02-9)


BODY CODE LEGEND




> Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Locking Hubs - Racheting Noise


Models


Subject


Index

FRONT AXLE

Date

November 19, 1984

No.






SYMPTOM RESOLUTION


free-wheeling hub.






CAUSE





> Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair

Blower Motor: Service and Repair


1. Disconnect battery ground cable.2. Remove instrument cluster outlined.3. Disconnect cable between blower motor and heater unit at connector.4. Working through instrument cluster panel mounting area, remove blower motor attaching bolts.5. Remove blower motor.6. Reverse procedure to install.

> Heating and Air Conditioning > Heater Core > Component Information > Service and Repair

Heater Core: Service and Repair


1. Disconnect battery ground cable, then place temperature control lever in Off position and drain cooling system.2. Remove parcel tray, center ventilation duct and grille and defroster duct.3. Disconnect heater hoses from heater core. Plug heater core fittings to prevent coolant spillage.4. Disconnect wire connector from blower motor.5. Remove bolts and nuts attaching heater assembly to dash panel, then the heater assembly.6. Remove heater core from heater assembly.7. Reverse procedure to install.

> Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications

Refrigerant: Capacity Specifications

A/C Refrigerant Specifications

Capacity .................................................................................................................................................................................................... 34 oz (2.13 lbs)

> Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1246

Refrigerant: Fluid Type Specifications

Fluid Type specifications

Type ................................................................................................................................................................................................. Refrigerant 12 (R-12)

> Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Technical Service Bulletins > Seat Belt Extender - Types/Identification

Seat Belt Extension: Technical Service BulletinsSeat Belt Extender - Types/Identification

Models

1983-1987 MMC Manufactured Vehicles (Imported For Chrysler) Except Sapporo/Challenger Models

Subject

Seat Belt Extender

Index

BODY

Date

September 15, 1986

No.

23-08-86

P-3235The front seat belt extender is intended for use only when the current seat belt is not long enough to fit around an occupant. It must be removed andstored when not required by that occupant.

Incorrect use of the seat belt extender, or any other extender which is not specified, may result in serious injury.

Four types of extenders have been released to be used in the combinations shown in the chart on page 2.

FIGURE 1

Install the seat belt extenders as shown in Figure 1.PARTS REQUIRED

Part No.

Type

Seat Belt Extender

Seat Belt Extender

*See chart on page 2

MB544778

MB544779

POLICY:

Model Year

Vehicle Model

Conquest

Information only

1983 1984

Type A

C*

D*

1985

Type A

1986

Type B

1987

(Not provided

> Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Technical Service Bulletins > Seat Belt Extender - Types/Identification > Page

1253

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

Colt

Raider

Ram 50, Power Ram 50

Colt Vista

Type A

Type A

Type A Type A Type B

Type A

Type D

Type A

Type D

Type B

Type C due to adoption of automatic seat belt)

Type B

Type B

Type B

Type C

> Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Reminder Buzzer: > 082684 > Nov > 84 > Radio - Speaker Noise

When Warning Buzzers Are ON

Seat Belt Reminder Buzzer: Customer InterestRadio - 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


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.


TIME ALLOWANCE: Refer to Labor Operation Time Schedule for Labor Operation and Time Allowance.

> Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Reminder Buzzer: > 082684 > Nov > 84 > Radio -

Speaker Noise When Warning Buzzers Are ON

Seat Belt Reminder Buzzer: All Technical Service BulletinsRadio - Speaker Noise When Warning Buzzers Are ON

Models


Subject


Index

ELECTRICAL

Date

November 23, 1984

No..

08-26-84



REPAIR PROCEDURE





> Restraint Systems > Seat Belt Systems > Seat Belt Warning Timer > Component Information > Locations

Seat Belt Warning Timer: Locations



> Accessories and Optional Equipment > Antenna > Component Information > Technical Service Bulletins > Radio - No AM/Weak FM Reception

Antenna: Technical Service BulletinsRadio - 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


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. Thiscondition 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.

> Accessories and Optional Equipment > Antenna > Component Information > Technical Service Bulletins > Radio - No AM/Weak FM Reception > Page 1275

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

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.


> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Radio - No AM/Weak FM Reception

Radio/Stereo: Technical Service BulletinsRadio - 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


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. Thiscondition 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.

> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Radio - No AM/Weak

FM Reception > Page 1281

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

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.


> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Page 1282

Radio/Stereo: Service and Repair

1.

Disconnect battery ground cable.

2.

Remove instrument cluster bezel as outlined in "Instrument Cluster, Replace."

3.

Remove radio bracket to instrument panel attaching screws, then the bracket.

4.

Pull radio slightly outward and disconnect antenna, speaker and feed leads, then remove radio from instrument panel.

5.


> Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Trailer Tow Wiring/Components - Installation Cautions

Trailer Adapter Kit: Technical Service BulletinsTrailer 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 wiringor 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 thetrailer 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 matingconnectors and do not require cutting or splicing of vehicle wiring. If cutting or splicing is required, the attached Wiring Procedure should befollowed.

^

When installing any electrical equipment (such as electric brakes, battery chargers, lighting, and winches) make sure that the tow vehicleselectrical ground is hard wired to the trailer electrical ground. Ground wires should be attached to a clean, bare metal surface, not to a paintedsurface. 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.

> Accessories and Optional Equipment > Towing / Trailer System > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Trailer Tow Wiring/

Components - Installation Cautions > Page 1288

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

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 untilit shrinks and seals the splice.

9.

Connect the battery.

> Body and Frame > Bumper > Component Information > Technical Service Bulletins > Synthetic Resin Bumpers - Painting

Bumper: Technical Service BulletinsSynthetic Resin Bumpers - Painting

Models

All 1984 & 1985 Imports

Subject

Index

BODY

Date

November 18, 1984

No..

23-21-84

P-5119-CService replacement bumpers available through Parts Supply are finished in a neutral (off white) shade. Proper preparation of these synthetic-resin(polyurethane and polypropylene) bumpers prior to painting is necessary.

NOTE: PLEASE ASSURE THAT YOUR BODY SHOP FOREMAN AND/OR PAINTER HAS THIS INFORMATION.

REFINISHING PROCEDURES

1.

Attach bumper to bumper core or support.

2.

Mask all areas which are not to be painted.

3.

Carefully water sand entire bumper area which is to be painted, using #400 or #600 water resistant sandpaper.

DO NOT REMOVE OFF WHITE PAINTED SURFACE FROM BUMPER.

4.

Degrease surface with wax and grease remover.

5.

Spray color coat onto bumper following paint manufacturer's instructions.

6.

Allow color coat to dry naturally (at room temperature) for approximately ten minutes, if clear coat is to be used.

CAUTION: DO NOT ALLOW DUST OR OTHER FOREIGN MATTER TO ADHERE TO PAINTED SURFACE.

7.

Spray clear coat onto bumper following paint manufacturer's instructions.

NOTE: STEPS (6) AND (7) ARE ONLY USED FOR PAINT COATS WITH METALLIC FINISH.

8.

Allow paint to dry.

CAUTION: IF PAINT IS GOING TO BE QUICK DRIED (OVEN OR HEAT LAMP), FIRST ALLOW IT TO AIR DRY FOR

APPROXIMATELY 15 MINUTES.


> Body and Frame > Frame > Cross-Member > Component Information > Service and Repair

Cross-Member: Service and Repair

Fig. 5 Location front suspension crossmember bolts

1. Install suitable jack under differential carrier.2. Remove front suspension crossmember from differential carrier assembly and from support bracket of side frame.3. Reverse procedure to install. Torque front suspension crossmember to support bracket of side frame bolt to 73-86 ft. lbs. Torque front suspension crossmember to bracket bolt to 22-30 ft. lbs.

> Body and Frame > Frame > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Trailer Tow Wiring/Components - Installation Cautions

Trailer Adapter Kit: Technical Service BulletinsTrailer 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 wiringor 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 thetrailer 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 matingconnectors and do not require cutting or splicing of vehicle wiring. If cutting or splicing is required, the attached Wiring Procedure should befollowed.

^

When installing any electrical equipment (such as electric brakes, battery chargers, lighting, and winches) make sure that the tow vehicleselectrical ground is hard wired to the trailer electrical ground. Ground wires should be attached to a clean, bare metal surface, not to a paintedsurface. 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.

> Body and Frame > Frame > Trailer Adapter Kit > Component Information > Technical Service Bulletins > Trailer Tow Wiring/Components - Installation Cautions > Page

1302

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

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 untilit shrinks and seals the splice.

9.

Connect the battery.

> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Synthetic Resin Bumpers - Painting

Paint: Technical Service BulletinsSynthetic Resin Bumpers - Painting

Models

All 1984 & 1985 Imports

Subject

Index

BODY

Date

November 18, 1984

No..

23-21-84

P-5119-CService replacement bumpers available through Parts Supply are finished in a neutral (off white) shade. Proper preparation of these synthetic-resin(polyurethane and polypropylene) bumpers prior to painting is necessary.

NOTE: PLEASE ASSURE THAT YOUR BODY SHOP FOREMAN AND/OR PAINTER HAS THIS INFORMATION.

REFINISHING PROCEDURES

1.

Attach bumper to bumper core or support.

2.

Mask all areas which are not to be painted.

3.

Carefully water sand entire bumper area which is to be painted, using #400 or #600 water resistant sandpaper.

DO NOT REMOVE OFF WHITE PAINTED SURFACE FROM BUMPER.

4.

Degrease surface with wax and grease remover.

5.

Spray color coat onto bumper following paint manufacturer's instructions.

6.

Allow color coat to dry naturally (at room temperature) for approximately ten minutes, if clear coat is to be used.

CAUTION: DO NOT ALLOW DUST OR OTHER FOREIGN MATTER TO ADHERE TO PAINTED SURFACE.

7.

Spray clear coat onto bumper following paint manufacturer's instructions.

NOTE: STEPS (6) AND (7) ARE ONLY USED FOR PAINT COATS WITH METALLIC FINISH.

8.

Allow paint to dry.

CAUTION: IF PAINT IS GOING TO BE QUICK DRIED (OVEN OR HEAT LAMP), FIRST ALLOW IT TO AIR DRY FOR

APPROXIMATELY 15 MINUTES.


> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Synthetic Resin Bumpers - Painting > Page 1308

Paint: Technical Service BulletinsPaint - Codes/Cross References

Models

All 1984 Domestic & Import Passenger Car & Truck

Subject

1984 Standard Colors

Index

BODY

Date

Sept, 1983

(current) No.

23-13-83Attached sheets list the Chrysler paint codes which are located on the vehicle body code plate. For location of the code plate see service manual. Asample domestic passenger car plate is enclosed for reference only. First three spaces on second line designates whether vehicle is monotone, two-tonecar, or two-tone truck.

APA - Monotone APB - Two-Tone Car APC - Two-Tone Truck


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

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 carsand 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, whocan assist your body shop personnel with recommended preparation and application procedures.


D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

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.


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 SalesCodes used to build a specific vehicle are listed in the ascending order by Alpha sequence.

> Body and Frame > Seats > Component Information > Technical Service Bulletins > Upholstery - Cleaning Procedure

Seats: Technical Service BulletinsUpholstery - 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 mayresult 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 or

Total Clean

REPAIR PROCEDURE

PN 4318015

PN 4318019

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:

POLICY:

DO NOT USE CARPET TYPE CLEANING APPARATUS THAT BLOWS IN SOLVENT OR STEAM, NOR ANY HOUSEHOLDCLEANERS NOT SPECIFICALLY RECOMMENDED FOR CLOTH UPHOLSTERY.

Information only

> Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations



> Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations



> Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component Information > Service and Repair

Instrument Cluster / Carrier: Service and Repair

1.

Disconnect battery ground cable.

2.

Pull off radio and heater control knobs.

3.

Remove adjusting nuts from radio and heater control stalks.

4.

Remove ashtray, then the ashtray bracket.

5.

Remove two cluster to dashboard attaching screws, then draw out cluster panel from lower left corner.

6.

Disconnect cluster wiring and speedometer cable, then remove cluster.

7.


> Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instrument Cluster - Odometer Memory Chip Service

Odometer: Technical Service BulletinsInstrument 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 caremust be exercised in handling the device during cluster or chip service. Refer to the procedure below for proper memory chip removal and installationprocedures.

DIAGNOSIS

Prior to servicing the instrument cluster, utilize the "Self-Diagnostic Test" procedure provided in the service manual to determine whether the cluster orthe 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 containsthe 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 chippackage and install per the following instructions.

NOTE:

REPLACEMENT OF THE ODOMETER CHIP IS PERMISSIBLE ONLY WHERE ORIGINAL MILEAGE MAY BE POSTED ON ADOOR 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 lastknown 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.

> Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instrument Cluster - Odometer Memory Chip

Service > Page 1334

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

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 inthe 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 chipalong 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 ODOMETERCHIP FROM DAMAGE BY PLACING IT IN AN ENVELOPE WITH THE VEHICLE VIN NUMBER AND MILEAGE.

> Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instrument Cluster - Odometer Memory Chip

Service > Page 1335

D50/Ram 50 L4-1997cc 2.0L SOHC (1984)

FIGURE 4

10.

Before inserting replacement odometer chip into cluster (or transferring existing odometer chip to new cluster), inspect pins of chip to assure theyare 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 thelip 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 intoposition 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 wasrecorded.

This bulletin is released in advance of parts availability. The parts listed in this bulletin will be available in mid-March, 1984.


FAILURE CODE:

0.4 Hrs.

08-70-02-02 Memory Chip With Original Mileage 0.4 Hrs.

58 - Internal Defect

TIME ALLOWANCE:Labor Operation No. 08-70-02-01 Memory Chip With Zero Mileage

> Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Reminder Buzzer: > 082684 > Nov > 84 > Radio -

Speaker Noise When Warning Buzzers Are ON

Seat Belt Reminder Buzzer: Customer InterestRadio - Speaker Noise When Warning Buzzers Are ON

Models


Subject


Index

ELECTRICAL

Date

November 23, 1984

No..

08-26-84



REPAIR PROCEDURE





> Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Reminder Buzzer: > 082684 > Nov > 84

> Radio - Speaker Noise When Warning Buzzers Are ON

Seat Belt Reminder Buzzer: All Technical Service BulletinsRadio - Speaker Noise When Warning Buzzers Are ON

Models


Subject


Index

ELECTRICAL

Date

November 23, 1984

No..

08-26-84



REPAIR PROCEDURE





> Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Technical Service Bulletins > Voltmeter - Explanation for High Readings

Volt Meter Gauge: Technical Service BulletinsVoltmeter - 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-CSYMPTOM/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 thatbuilds up places the voltmeter indicator toward the high end of the "normal" operating portion of the meter or, under the right conditions, may just enterthe "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 higherthan hot temperature operation).

^ Instrument cluster illumination lamps and/or heater/defroster on, which increases temperatures around the voltmeter.

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.


If a high voltmeter reading exists, verify battery and charging system are operating normally per service manual procedures. If system meetsspecifications, assure customer that system is operating properly. Do not replace voltage regulator or voltmeter if test results meet service manualspecifications.

> Lighting and Horns > Brake Light Switch > Component Information > Service and Repair




> Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations

Hazard Warning Flasher: Locations



> Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations




> Lighting and Horns > Headlamp > Headlight Switch <--> [Headlamp Switch] > Component Information > Service and Repair



> Lighting and Horns > Horn > Component Information > Technical Service Bulletins > Customer Interest for Horn: > 082284 > Aug > 84 > Horn - Intermittently Inoperative

Horn: Customer InterestHorn - Intermittently Inoperative

Models

All 1983-1984 Equipped with Tilt Steering

Subject

Intermittent Horn Operation on Tilt Column

Index

ELECTRICAL

Date

August 6, 1984

No..

08-22-84


Intermittent horn operation on tilt steering column.

Since there is no rotation between the steering wheel pick-up ring and the mating horn brush on a tilt column, any grease present may act as an insulator.

REPAIR PROCEDURE

1.

Tilt Column Only

Remove the ignition key from the key cylinder. Rotate the steering wheel to insure that the column is locked.

2.

Remove the steering wheel.

3.

Thoroughly remove all lube from the steering wheel pick-up ring and the mating horn brush using mineral spirits. It is very important that bothsurfaces be cleaned thoroughly. Do not sand the ring or relube it.

4.

Replace the steering wheel.

5.

Check horn operation.


0.2 Hrs.

FAILURE CODE: 61 - Intermittent Operation

> Lighting and Horns > Horn > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Horn: > 082284 > Aug > 84 > Horn - Intermittently Inoperative

Horn: All Technical Service BulletinsHorn - Intermittently Inoperative

Models

All 1983-1984 Equipped with Tilt Steering

Subject

Intermittent Horn Operation on Tilt Column

Index

ELECTRICAL

Date

August 6, 1984

No..

08-22-84


Intermittent horn operation on tilt steering column.

Since there is no rotation between the steering wheel pick-up ring and the mating horn brush on a tilt column, any grease present may act as an insulator.

REPAIR PROCEDURE

1.

Tilt Column Only

Remove the ignition key from the key cylinder. Rotate the steering wheel to insure that the column is locked.

2.

Remove the steering wheel.

3.

Thoroughly remove all lube from the steering wheel pick-up ring and the mating horn brush using mineral spirits. It is very important that bothsurfaces be cleaned thoroughly. Do not sand the ring or relube it.

4.

Replace the steering wheel.

5.

Check horn operation.


0.2 Hrs.

FAILURE CODE: 61 - Intermittent Operation

> Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations




> Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair




> Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlight Switch <--> [Headlamp Switch] > Component Information > Service and Repair



> Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair




> Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations

Turn Signal Flasher: Locations



> Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair




> Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations




> Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Customer Interest for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield

Wiper Blade: Customer InterestWipers/Washers - Wipers Smear or Streak Windshield

NUMBER: 23-014-06

GROUP: Body

DATE: March 8, 2006

SUBJECT:Windshield Wiper Blade/Element Maintenance

All Chrysler Group Vehicles MODELS:All All

DISCUSSION:

Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film canbuild up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, achattering 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 thewiper 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 beperformed:

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 of50/50 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 thewindshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. Ifthe 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.

> Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak

Windshield

Wiper Blade: All Technical Service BulletinsWipers/Washers - Wipers Smear or Streak Windshield

NUMBER: 23-014-06

GROUP: Body

DATE: March 8, 2006

SUBJECT:Windshield Wiper Blade/Element Maintenance

All Chrysler Group Vehicles MODELS:All All

DISCUSSION:

Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film canbuild up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, achattering 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 thewiper 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 beperformed:

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 of50/50 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 thewindshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. Ifthe 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.

> Wiper and Washer Systems > Windshield Wiper Transmission <--> [Wiper Gear Box] > Component Information > Service and Repair

Windshield Wiper Transmission: Service and Repair

EXC. 1984 COLT HATCHBACK

1. Remove wiper motor as outlined under "Windshield Wiper Motor, Replace."2. Position wiper motor shaft at right angles to the linkage and remove linkage while holding shaft.3. Reverse procedure to install, noting the following: a. Ensure shaft bracket positioning boss is properly located in access hole.b. Mount wiper arm so that when motor is in park position distance between wiper blade and bottom of windshield is 0.6 inch on left side and

0.8 inch on right side for 1985-88 Colt, 1.2 inch on left side and 1 inch on right side for Colt Vista, 0.5 inch on both sides for Conquest, 0.6-1inch on both sides for Ram 50 and 1.5-1.9 inch on both sides for Ram Raider.

> Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair

Wiper Motor: Service and Repair

FRONT WIPER

1. Disconnect battery ground cable and remove wiper motor access hole cover, located on the left hand side of the front deck, if applicable.2. Raise covers and remove nuts securing wiper arms to pivot shafts, note installation position of arms, then remove wiper arms.3. Remove cowl moldings, as needed, to gain access to pivot shaft fasteners.4. Remove wiper pivot shaft attaching bolts or nuts, then push pivots inwards.5. Remove wiper motor attaching bolts or nuts, pull motor out slightly and disconnect linkage. Mark relationship of wiper motor crank arm to driveshaft prior to disconnecting linkage to ensure proper stop angle after installation.

6. Remove wiper motor.7. Reverse procedure to install. When installing crank arm on wiper motor, ensure reference marks made during removal are aligned, then install wiper arms as outlined in "Windshield Wiper Transmission, Replace."

> Wiper and Washer Systems > Wiper Relay > Component Information > Locations




Dodge RAM 1997 Workshop Manual

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