Chilton's Chrysler Full-Size Trucks 1967-88 Repair Manual [20400] 0801986621, 9780801986628

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full-size trucks

CHRYSLER VI II WMMM 1 1

20400

'

I

iQQj_QQ f^EPAIR

MANUAL

Covers all U.S. and Canadian models of Dodge/Plymouth 1/2, 3/4 and 1-ton Pick-Ups, Chassis Cab, Ramcharger and Trail Duster; 2 and 4 wheel drive, gasoline and diesel engines

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Digitized by the Internet Archive in

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http://www.archive.org/details/chiltonschryslerOOhoch

FULL-SHE TRUCKS 1967-88 REPAIR MANUAL

CHRYSLER

Covers all U.S. and Canadian models of Dodge/Plymouth 1/2, 3/4 and 1-ton Pick-ups, Chassis Cab, Ramcharger and Trail Duster; 2 and 4 wheel drive, gasoline and diesel engines

by

Dawn M. Hoch, sae. Automot/ve

Books PUBLISHED BY HAYNES NORTH AMERICA.

Manufactured

©

in

Inc.

USA

1995 Haynes North America,

Inc.

ISBN 0-8019-8662-1 Library of

Congress Catalog Card No. 94-069445

7890123456 9876543210

Haynes Publishing Group Sparkford Nr Yeovil

Somerset BA22 7JJ England

Haynes

Nortli

America, Inc

861 Lawrence Drive

Newbury Park 320 USA

12G1

California 91

Chilton

Is

a registered trademark of W.G. Nichols,

Inc.,

and has been licensed

to

Haynes North America,

Inc.

Contents GENERAL INFORMATION AND MAINTENANCE

1-2

HOW

1-2

TOOLS AND EQUIPMENT

1-4

SERVICING YOUR VEHICLE SAFELY

1-41

PUSHING AND TOWING

1-41

JACKING

FASTENERS,

1-42

MAINTENANCE AND LUBRICATION CHARTS

1-5

TO USE THIS BOOK

1-12 1-27

MEASUREMENTS AND

ROUTINE MAINTENANCE FLUIDS AND LUBRICANTS

CONVERSIONS

1-7

SERIAL

NUMBER

IDENTIFICATION

ENGINE PERFORMANCE AND TUNE-UP

ENGINE AND ENGINE

2-2

TUNE-UP PROCEDURES

2-20

IGNITION TIMIN&

2-8 2-9

FIRING

ORDERS

2-21

VALVE LASH

2-22

2-11

ELECTRONIC IGNITION

IDLE SPEED AND MIXTURE ADJUSTMENTS

3-2

ENGINE ELECTRICAL

3-57

EXHAUST SYSTEM

3-10

ENGINE MECHANICAL

4-2

EMISSION CONTROLS

4-8

ELECTRONIC ENGINE

POINT TYPE IGNITION

OVERHAUL

EMISSION CONTROLS

4-12 VACUUM

DIAGRAMS

CONTROLS

5-2

BASIC FUEL SYSTEM

5-36 THROHLE BODY

FUEL SYSTEM

FUEL

INJECTION SYSTEM

DIAGNOSIS

5-2

CARBURETED FUEL SYSTEM

5-41

DIESEL FUEL SYSTEM

5-27

CARBURETED SPECIFICATIONS CHARTS

5-43

FUEL TANK

UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS

6-18

INSTRUMENTS AND SWITCHES

6-21

LIGHTING

HEATER AND AIR CONDITIONER

6-24 6-24 6-28

TRAILER WIRING

RADIO

WINDSHIELD WIPERS AND

WASHERS

CIRCUIT PROTECTION

WIRING DIAGRAMS

Contents 7-2

MANUAL TRANSMISSION

7-18

DRIVEUNE

7-6

CLUTCH

7-21

FRONT AXLE DRIVE

7-11

TRANSFER CASE

7-33

REAR AXLE

7-1

AUTOMATIC TRANSMISSION

8-2

WHEELS

8-19

REAR SUSPENSION

8-3

FRONT SUSPENSION

8-21

STEERING

SUSPENSION

AND STEERING

9-2

HYDRAULIC BRAKING

9-11

FRONT DISC BRAKES

SYSTEM

9-16 9-20

REAR

10-6

INTERIOR

9-9

FRONT DRUM BRAKES

10-2

EXTERIOR

DRUM BRAKES

PARKING BRAKE

BODY AND TRIM

10-11 GLOSSARY

1

0-1 5 MASTER

INDEX

SAFETY NOTICE

Proper service and repair procedures are

all motor vetiicles. as well as ttie personal safety of ttiose perand repairing vehicles using safe, effective methods. The procedures contain many

the safe, reliable operation of

vital to

forming repairs. This manual outlines procedures

for servicing

NOTES, CAUTIONS and WARNINGS which should be followed, along with standard procedures improper service which could damage the vehicle or compromise its safety.

It

is

to eliminate the possibility of personal injury or

important to note that repair procedures and techniques, tools and parts for servicing motor vehicles, as well as the skill and experience of It is not possible to anticipate all of the conceivable ways or conditions under which vehicles may to provide cautions as to all possible hazards that may result. Standard and accepted safety precautions and equipment should be

the individual performing the work vary widely

be serviced, or

used when handling toxic or flammable

fluids,

and safety goggles or other protection should be used during

cutting, grinding, chiseling, prying,

or any other process that can cause material removal or projectiles.

Some

procedures require the use of tools specially designed for a specific purpose. Before substituting another tool or procedure, you must be safety, nor the performance of the vehicle will be endangered.

completely satisfied that neither your personal

Although information

in this

manual

is

based on industry sources and

is

complete as possible

at the time of publication, the possibility exists

some car manufacturers made later changes which could not be included here. While striving for total accuracy, cannot assume responsibility for any errors, changes or omissions that may occur in the compilation of this data. that

the authors or publishers

PART NUMBERS

Part

ences

numbers

that

listed in this reference are not recommendations by Haynes North America, Inc. for any product brand name. They are refercan be used with interchange manuals and aftermarket supplier catalogs to locate each brand supplier's discrete part number.

SPECIAL TOOLS

Special tools are

recommended by

the vehicle manufacturer to perform their specific job.

absolutely necessary, they are referred to priate part let.

in the text

Use has been kept

to a

minimum, but where

by the part number of the tool manufacturer These tools can be purchased, under the approdistributor, or an equivalent tool can be purchased locally from a tool supplier or parts out-

number, from your local dealer or regional

Before substituting any tool for the one recommended, read the

SAFETY NOTICE

at the top of this page.

ACKNOWLEDGMENTS The

publisher expresses appreciation to Chrysler Corporation for their generous assistance.

All rights

reserved.

No

part of this

ing photocopying, recording or

book may be reproduced or transmitted

by any information storage or

is made to ensure that the damage or injury caused by any

While every attempt

information

lishers for loss,

errors

in,

retrieval

in this

any form or by any means, electronic

in

system, without permission

manual

is

correct,

no

liability

in

or mechanical, includ-

writing from the copyright holder.

can be accepted by the authors or pub-

or omissions from, the information given.

USE THIS BOOK 1-2 WHERE TO BEGIN 1-2

FLUIDS AND LUBRICANTS 1-27

AVOIDING TROUBLE

FUEL AND ENGINE OIL RECOMMENDATIONS 1-27 GASOLINE ENGINES 1-27 DIESEL ENGINES 1-27

HOW TO

FLUID DISPOSAL 1-27

1-2

MAINTENANCE OR REPAIR?

1-2

MOST COMMON MISTAKES TOOLS AND EQUIPMENT 1-2 AVOIDING THE

SPECIAL TOOLS

1

-2

ENGINE 1-27 OIL LEVEL CHECK 1-28

1-4

SERVICING YOUR VEHICLE SAFELY

OIL AND FILTER CHANGE 1-28 MANUAL TRANSMISSION 1-29 FLUID RECOMMENDATIONS 1-29 LEVEL CHECK 1-30 DRAIN AND REFILL 1-30

1-4

1-4

DO'S

OONTS

1-5

FASTENERS, MEASUREMENTS AND

CONVERSIONS BOLTS, NUTS

1-5

AUTOMATIC TRANSMISSION

AND OTHER THREADED

RETAINERS

TORQUE 1-6 TORQUE WRENCHES 1-6 TORQUE ANGLE METERS 1-6 STANDARD AND METRIC MEASUREMENTS SERIAL NUMBER IDENTIFICATION 1-7 '

VEHICLE IDENTIFICATION NUMBER 1967-69 MODELS 1-7

(VIN)

TRANSFER CASE 1-7

1-7

FLUID

1-32

RECOMMENDATIONS

DRAIN AND REFILL 1-33

RECOMMENDATIONS

FLUID

LEVEL CHECK 1-34

1980-88 MODELS 1-8 1-9

ENGINE 1-9

TRANSFER CASE 1-12 MANUAL TRANSMISSIONS 1-12 AXLES 1-12

ROUTINE MAINTENANCE 1-12 1-12

REMOVAL & INSTALLATION

1-12

FUEL FILTER 1-13

REMOVAL & INSTALLATION 1-13 CRANKCASE VENTILATION SYSTEM 1-14 TROUBLESHOOTING 1-15 REPLACEMENT 1-15

POSITIVE

EVAPORATIVE CANISTER 1-15 SERVICING 1-15

BAnERY

1-16

PRECAUTIONS 1-16 GENERAL MAINTENANCE 1-16 BATTERY FLUID 1-16 CABLES 1-17

1-20

FLUID RECOMMENDATIONS 1-23

DRAINING & REFILLING THE SYSTEM 1-23

FLUSHING & CLEANING THE SYSTEM 1-23 AIR CONDITIONING SYSTEM 1-23 SYSTEM SERVICE & REPAIR 1-23 PREVENTIVE MAINTENANCE 1-24 SYSTEM INSPECTION 1-24 WINDSHIELD WIPERS 1-24 ELEMENT (REFILL) CARE & 1-24 1-24

TIRE ROTATION 1-25 TIRE DESIGN 1-25

STORAGE

INFLATION

1-25

& INSPECTION

1-41

1-41

1967-69 MODELS 1-41

AND LATER MODELS 1-41 MAINTENANCE AND LUBRICATION CHARTS 1-42 SPECIFICATIONS CHARTS ENGINE IDENTIFICATION SPECIFICATIONS 1-10 MAINTENANCE INTERVALS

INSPECTION 1-22

TIRE

1-38

1970 1-21

1-22

AND WHEELS

BODY LUBRICATION AND MAINTENANCE CARE OF YOUR TRUCK 1-38 HOOD LATCH AND HINGES 1-38 TAIL GATE AND DOOR HINGES 1-39 FRONT WHEEL BEARINGS 1-39 REMOVAL, REPACKING, &

TOWING 1-41 COOLING 1-41 JACKING 1-41

HEAT RISER 1-22 SERVICING 1-22

REPUCEMENT

CHASSIS GREASING 1-37 STEERING LINKAGE 1-38 PARKING BRAKE LINKAGE 1-38 AUTOMATIC TRANSMISSION LINKAGE 1-38

INSTALLATION 1-39

INSPECTION 1-18

TIRES

FLUID RECOMMENDATIONS 1-34 LEVEL CHECK 1-35 POWER STEERING PUMP 1-35 FLUID RECOMMENDATIONS -35 LEVEL CHECK 1-35 BRAKE MASTER CYLINDER 1-36 LEVEL CHECK 1-36 FLUID RECOMMENDATIONS 1 -36 HYDRAULIC CLUTCH RESERVOIR 1-37

PUSHING

BELTS 1-18

COOLING SYSTEM

1-34

DRAIN AND REFILL 1-34 STEERING GEAR 1-34

PUSHING AND TOWING

CHARGING 1-18 REPLACEMENT 1-18

ADJUSTMENTS 1-19 REMOVAL & INSTALLATION HOSES 1-21 REMOVAL & INSTALUTION

1-32

DRIVE AXLES 1-34

1974-79 MODELS 1-8

CLEANERS

1-31

LEVEL CHECK 1-33

1970-73 MODELS 1-7

EQUIPMENT IDENTIFICATION PLATE

AIR

1-31

RECOMMENDATIONS LEVEL CHECK 1-31 DRAIN AND REFILL 1-31 FLUID

1-5

1-25

SPECIFICATIONS 1-43 DIESEL MAINTENANCE INTERVALS

SPECIFICATIONS 1-43 CAPACITIES 1-44

HOW TO USE

THIS BOOK TOOLS AND EQUIPMENT VEHICLE SAFELY YOUR SERVICING

1-2 1-2 1-4

FASTENERS, MEASUREMENTS SERIAL

AND CONVERSIONS NUMBER IDENTIFICATION

1-5 1-7

ROUTINE MAINTENANCE 1-12 FLUIDS AND LUBRICANTS 1-27

PUSHING AND TOWING JACKING

1-41 1-41

MAINTENANCE AND LUBRICATION CHARTS 1-42

GENERAL INFORMATION AND MAINTENANCE

1-2 HOW

TO USE THIS BOOK Dodge and Plymouth Trucks

This Chilton's Total Car Care manual for

Two basic mechanic's

is

intended to help you learn more about the inner workings of your vehicle while

money on

saving you

The beginning where you

upkeep and operation.

its

book

of the

more complex systems

through brakes) are covered

book

attempt. This

most, since that

to the

of

to the extent that the

own

brake pads and shoes, replace spark plugs, and perform

that

can save you money and help avoid expensive problems.

A secondary purpose

book

of this

is

many more

a reference for owners

who want

jobs

Pay attention

what tools and supplies

overall view of

be required. So read ahead

will

proce-

all

component

repair of a

we

not considered practical,

is

and then how

part

new

to install the

taking apart something that

you how

tell

to

of lines,

vehicle

may

—

may

to "label

and disconnect

."a

.

.

hoses or wires. Don't be think you can remember where every-

you won't.

you hook up vacuum or

If

run poorly,

don't need to

at all.

if

know

If

you hook up

the proper

masking tape on the hose and

own

label.

a piece

you

electrical wiring incorrectly,

if

a part

its fitting will

Remember

marking metal

felt-tipped

parts.

line.

A

allow you to assign your

remember

many

times

is

that

if

so

lines

is

come

can be recon-

Loctite®).

If

in the

order

compound, read

ing

tape or paper labels after assembly.

make sure you

of

with

is

it

deterioration. Repair implies that

need

and

something has broken or

caused by lack

for a repair is often

automatic transmission

refilling

cific intervals. Failure to

do

this

of

maintenance,

fluid is

is

for

wear or

for

not working.

can shorten the

at

spe-

transmlssion/transaxle, requiring very expensive repairs. While no maintenance

program can prevent items from eventually breaking or wearing rule is true:

MAINTENANCE

IS

if

access

unscrew

tance,

inserted

a torque wrench

in

you are using the

right tool to tight

overtorquing

pay attention

parts,

assembly

for

loose causing

to vibrate

to

a torque figure

If

is

perform the job, you

enough. The pitch

you put on the wrench

will

of

be multiplied

ensuring that fasteners

for

they are not torqued just right (a very

if

to

common

brand

enough

damage during assembly, one

avoid mechanical

the label

on the package and make sure the product

to

of

is difficult.

the part

when a

such as a

part

bolt is is

screwed

more

into a

likely to

helps to clean and lubricate fasteners, then to start

It

and

is

fluids, etc. involved.

start

over again

If

you encounter

at a different

and turned several times without much

effort.

part you're threading to the proper angle. Don't put a

been tightened a couple

and the

of the

life

in

angle

Keep

in

until

mind

it

resis-

can be

that

many

parts have tapered threads, so that gentle turning will automatically bring the

A

example: draining

maintenance recommended

you're

the proper

in

more common

aluminum

threading the bolt, spark plug, etc. with your fingers.

normal wear Maintenance compensates

When

it.

get everything back

adjustments, perform them

Crossthreading. This occurs

occur

of

which the

in

for

you're worried about getting something together tight

enough

taking

these products might offer substantial insurance. Before choosing a threadlock-

3.

Maintenance includes routine inspections, adjustments, and replacement

When

on what you are tightening.

compatible with the materials,

for

Maintenance or Repair? which show signs

in

wrong order usu-

the

nut or casting at the wrong angle and forced. Crossthreading

parts

mistakes

will affect another.

slight that the tension

loose, even

in

see a reason

can't

order to

when dealing

utilize

actual force

in

hold, but loose

that tape will dissolve in gasoline or

marker or a metal scribe can be very handy

Remove any

you

probably not have to strain yourself to get a fastener

will

won't

piece of

be washed or cleaned, use another method of identifica-

is to

A permanent

tion.

on

common

break something. Read the entire

There are many commercial products available

each hose or

for

As long as you remember your own code, the

nected by matching your tags. solvents:

name

it

Overtorquing (or undertorquing). While

not available,

instantly learn a very expensive lesson.

You

CAN

it

cause damage, undertorquing may allow a fastener

most threads

fuel lines incorrectly, the

in

When making

torque specifications and

book require you

There are 3

very intricate, you might want to draw a picture of

One adjustment possibly

order. 2-

Avoiding Trouble

group

it

proper position.

its

or rebuilt replacement. In this

is

looks when assembled

serious damage. Especially

in this

Mistakes

together, performing steps

it

you extra time: however,

instructions say you should, even

to

Many procedures

Common

procedure before beginning. Perform everything

save labor costs.

at least

thing goes

SERVICING YOUR VEHICLE

acknowledgment page.

the

Incorrect order of assembly, disassembly or adjustment.

.

how

dures thoroughly understood before attempting any work.

way, you

Constantly be aware of the dangers

rule.

section regarding

to the instructions provided.

something apart or putting

to Begin.

and plan ahead. Each operation should be approached logically and

If

Con-

mechanical work:

Before removing any bolts, read through the entire procedure. This will give

remove the

in this

SAFETY NOTICE on

the

ally just costs

you the

the driver's side.

working on an automobile and take the proper precautions. Piease information

Avoiding the Most

1

Where

always the most important

is

in

SAFELY and

to

and/or their mechanics better

their vehicle

understand

whenever the

here. First,

means

it

the passenger's side. Second, screws

however, give you detailed instructions to help you change your

will,

It

involved

refer to the

uneco-

this

means

removed by turning counterclockwise, and tightened by turning

bolts are

Safety

average do-it-yourselfer can

explain such things as rebuilding a differential

will not

referred to,

is

clockwise unless specifically noted.

your vehicle. Systems (from engine

because the expertise required and the special tools necessary make nomical.

and

is

information for maintenance and tune-up. The other sections

will find

deal with the

be referred

will likely

mentioned

rules should be

side of the vehicle or engine

left

versely, the right side of the vehicle

of turns

has not seated

fully,

by hand.

wrench on the

part until

it's

you suddenly encounter resistance,

If

don't force

Pull

it.

it

back out

to

make sure

it's

clean and threading properly.

Be sure

out, a general

self

CHEAPER THAN REPAIR.

part

to take your time

ample time

to

and be

and always plan ahead. Allow your-

patient,

perform repairs and maintenance.

TOOLS AND EQUIPMENT I See Figures

1

Begin accumulating those tools that are used most frequently: those associ-

thru 15

ated with routine maintenance and tune-up.

Without the proper tools and equipment your vehicle.

would need

It

would be perform

to

virtually

all

the amateur to rush out

or

more

is

to

tools.

It

is far

most

better to

or 12-point sockets

every tool that you

of

them

at

set of tools

some

on the theory

a

little

more

for

that

for better quality.

by

of

of

those

bargain

Forged wrenches, 6

far preferable to their less

in.

and/or

3mm-19mm W^e

in.

or

%

in.

in sizes

spark plug socket (depending

type).

buy various length socket drive extensions. Universaland wobble extensions can be extremely useful, but be careful when using them, as they can change the amount of torque applied to >»lf possible, joint

the socket. •

Jackstands

experiences than trying to work on a vehicle with bad tools. Your monetary sav-

•

Oil filter

outweighed by frustration and mangled knuckles.

•

Spout or funnel

far

addition to the normal assortment

Wrenches/sockets and combination open end/box end wrenches

V8-%

on plug

you, there are few worse

expensive counterparts. As any good mechanic can

ings will be

In

screwdrivers and pliers, you should have the following tools:

time.

be misled by the low cost

fine tooth ratchets are

of

•

would be unwise

It

proceed slowly, gathering a good quality set

frequently. Don't

spend

and

impossible to properly service

of the operations in this book.

may need one

tools that are used

is

to catalog

and buy an expensive

The best approach

he/she

it

impossible

tell

for support.

wrench. for

pouring

fluids.

GENERAL INFORMATION AND MAINTENANCE

1-3

^SftSWJS* ^

The system

See Figures 46 and 47

The carburetor With the engine running,

pull the

PCV

valve and hose from the valve rocker

cover rubber grommet.

A is

over the valve

vacuum If

the

valve

is

hose and

PCV

valve

the valve

a finger

it

inside the valve

free

is

inlet,

check

and

is

not

trucks, or

connections.

On

shaken. This indicates that the metal check

gummed

up.

If

no noise

is

ball

and on most vehicles sold

in

the U.S. there-

to replace the valve

if

it

is

through the charcoal canister.

either vented internally or

is

which

to the canister

PCV

filter

light

sooner

with activated charcoal, provid-

is filled

On some models you can

replace the

engine

engines, a bi-level system

at idle

and

off-idle as well.

is

used

The source

in

element

which vapors are drawn

of idle

system. The only service associated with the system

element

filter

done every 30,000 miles

duty trucks, 18,000 miles (29.000 km) on heavy duly

dusty conditions.

in

fuel injected

into the

the

heard, clean or

replace the valve. Since these valves are normally inexpensive components,

would probably be smartest

California

located at the bottom of the canister. This should be

(48,000 km) on

disconnected from the engine, a metallic clicking noise

should be heard when is still

at the

If

when you place

felt

While you have your finger over the

inlet.

leaks in the

PCV

Vapors are routed

ing temporary storage.

hissing noise should be heard as air passes through the valve.

working properly, a strong vacuum should be

for

in

designed to prevent evaporated gasoline vapors from escap-

is

ing into the atmosphere.

in the

base

vacuum is

is

a tee

a replaceable

of the canister.

it

suspect.

SERVICING

REPLACEMENT The vapor storage canister gear, Pull the

PCV

2.

Remove

the

3.

Inspect the inside of the valve hose.

1

valve and hose from the rubber

grommet

in

the rocker

cover,

is

located on the

left

frame

on models through 1972. On 1973-87 models

truck, next to the right side

frame

rail,

it

is

rail,

behind steering

located under the

and behind the transmission support

crossmember.

intake manifold

PCV

valve from the hose.

and clean

it

in

If

On 1988 models, it

is dirty,

a suitable, safe solvent.

disconnect

it

from the

the canisters for

area of the engine compartment. tanks.

These are

identical

all

engines are located

Some models

in

the wheel-well

are equipped with two storage

and should be serviced

together.

in

GENERAL INFORMATION AND MAINTENANCE

1-16

Do in

CARBURETOR VENT LINE AS APPLtCABLE

smoke

not

open llames/sparks near

or all

the battery are very explosive and,

gases contained

a battery; the

cause severe injury or

ignited, could

if

death.

regardless of type, should be carefully secured by a battery

All batteries,

hold-down device.

If

A

vehicle operation. it

discharge

casing

not, the terminals or

battery

which

is

The acid can also

faster.

Always inspect the battery case

not secured

away

eat

at

may may

crack from stress during allow acid to leak, making

components under

the hood.

A

leakage and corrosion.

for cracks,

white

corrosive substance on the battery case or on nearby components would indicate a leaking or cracked battery.

If

the battery

is

cracked,

it

should be replaced

immediately.

GENERAL (\^AINTENANCE DISTRIBUTOR

Always keep the battery cables and terminals clean these

components about once a

Keep the top

Check and

of the battery clean, as a film of dirt can help discharge a bat-

used

tery that is not

free of corrosion.

year.

for

A

long periods.

solution of baking soda and water

EVAPORATION CONTROL SYSTEM be used for cleaning, but be careful to flush this

any

ott

with clear water.

may

DO NOT

let

Baking soda neutralizes battery acid and

of the solution into the filler holes.

will de-activate a battery cell.

Fig.

48 Vapor Saver Evaporation Control System (VSECS)

which are not operated on a regular basis can

Batteries in vehicles to parasitic

from the in

fall

victim

loads (small current drains which are constantly drawing current

Normal

battery).

parasitic loads

may

drain a battery on a vehicle that

6-8 weeks. Vehicles that have additional accesan alarm system may discharge a battery sooner.

is

storage and not used for

sories such as a the vehicle

tem

is

phone

or

stored for longer periods

is to tie

in

If

a secure area and the alarm sys-

not necessary, the negative battery cable should be disconnected to pro-

tect the battery.

Remember

that constantly

and recharging

will

it)

deep cycling a battery (completely discharging

shorten battery

life.

BATTERY FLUID t

See Figure 51 Check

the battery electrolyte level at least

once a month, or more often

weather or during periods of extended vehicle operation. ies,

Fig.

49 An emission hose diagram stiould be found on a label

In the

the level can be checked either through the case

removing the

cell

caps. The electrolyte level

the split ring inside each cell, or the line

engine compartment

If

is

the level

correct.

is

Each

low, cell

add

in

each

(if

On non-sealed

cell

should be kept

marked on the outside

only distilled water

must be checked and

most drinking

in

water are harmful to the battery and could significantly shorten water

is

added

in

filled to

until the level

individually Distilled water

should be used, because the chemicals and minerals found

If

hot

of the case.

through the opening

filled

in

batter-

translucent) or by

its life.

freezing weather, the vehicle should be driven several

miles to allow the water

to

mix with the

electrolyte. Otherwise, the battery

could

freeze.

Although some maintenance-free batteries have removable electrolyte condition

checked using the

most

and

level

built-in

on

all

cell

caps, the

sealed maintenance-free batteries must be

hydrometer "eye." The exact type

of

eye

will vary. But,

battery manufacturers, apply a sticker to the battery itself explaining the

readings.

Fig.

50 The vapor canister

Is

easily

removed

after releasing the

retainer(s)

PRECAUTIONS Always use caution when working on to bridge the

caretui not to allow a tool to provide a nal

or near the battery.

ground between

and any metal component on the vehicle.

cause a short

Never allow a tool

gap between the negative and positive battery terminals. Also, be

circuit,

the positive cable/ternni-

Either ot these conditions will

leading to sparks and possible personal injury.

Fig. 51

Maintenance-free batteries usually contain a

hydrometer

to

check

fluid level

built-in

GENERAL INFORMATION AND MAINTENANCE v^Although the readings from

built-in

hydrometers

green eye

will vary, a

usually Indicates a properly charged battery with sufficient fluid level.

normally an indicator

dark eye

is

which

low

is

trolyte

in

A

of a battery with sufficient fluid, but

from

charge. A light or yellow eye usually indicates that elec-

has dropped below the necessary level.

batteries with an insufficient electrolyte

In this last

The

case, sealed

must usually be discarded.

battery testing hydrometer has a squeeze bulb at

the other Battery electrolyte

If

its

The specific

seat.

gravity

is

low

checked again

gravity

one or more

in

to

sucked

is

see

if

any two

battery should be replaced, as

it

one end and a nozzle

hydrometer

come

cells varies

at

until the float is lifted

then read by noting the position of the

is

cells, the battery

the gravity has

specific gravity between

Checking the Specific Gravity

into the

1-17

float.

should be slowly charged and

up. Generally,

charging, the

after

if

more than 50 points

(0,50), the

can no longer produce sufficient voltage

to

guarantee proper operation,

I See Figures 52, 53 and 54

CABLES A hydrometer

is

required to check the specific gravity on

not maintenance-free. is

On

all

batteries that are

batteries that are maintenance-free, the specific gravity

checl

See Figures 59, 60, 61, 62 and 63 Once a year

Fig.

58 The cable ends should be cleaned as well

or at 12,000 mile (19,000

power

tion) of the alternator,

pump

drive belts (as equipped) should be checked.

engine cooling and diminish

compressor or

CAUTION

air

components

the

it

pump is

charge

until

to bring

and Thermactor

they are

them back

slow

rate to

keep the plates inside from get-

some maintenance-free batteries are allowed to disalmost "dead," they may have to be charged at a high rate

However,

it

to "life."

Always follow the charger manufacturer's instruc-

tions on charging the battery.

A

necessary, the belts

If

power steering pump,

is

air

belt that is too tight places a

so glazed, worn

condi-

air

component

or stretched that

different types ol belts that

it

to

poor

conditioning

severe strain on failure.

cannot be tight-

may be found on

your truck, v-belts (single ribbed) and serpentine type (multi-ribbed). Both of these types

not battery should be charged at a

output.

ened sufficiently There are two

may

drive

>»The material used

ing with or near a battery.

alternator,

driving which will lead to early

Replace any belt that

The chemical reaction which takes place in all batteries generates explosive hydrogen gas. A spark can cause the battery to explode and splash acid. To avoid personal injury, be sure there Is proper ventilation and take appropriate fire safety precautions when work-

A

intervals, the tension (and

should be replaced or adjusted. Loose accessory drive belts can lead

CHARGING

ting too hot.

km)

steering, air conditioning,

show wear as

On

in late

readily.

model

drive belts

such that the belts do

Is

at least every three years.

Replace belts

vehicles with matched belts, replace both belts.

wide belts are

to

adjusted to 80

been operating first

one or more accessories.

be adjusted to a tension

lbs. (as

lor a

10 minutes, the

measured on

minimum belt

of

ol

a belt

140

to

New

Vs,

and Va

in.

tension gauge). Any

10 minutes

should stretch

lbs.

is

its

% and i%2

considered a used

maximum

in.

wide belts are belt that

has

belt. In

extent. After

the

10 min-

CONVENTIONAL

TCCS1215

Fig.

Fig. 61

59 There are typically 3 types of

Deep cracks

in this belt will

cause

up heat that will eventually

accessory drive belts found on vehicles

flex, building

today

lead to belt failure

/ Fig.

62 The cover

of this belt is

ing cords to excessive

wear

worn, exposing the

critical reinforc-

Fig.

63 Installing too wide a

and/or breakage

belt

can result

in

serious belt wear

GENERAL INFORMATION AND MAINTENANCE utes, stop the

engine and rectieck

110

stiould be maintained at

Vt

in.

dures

wide

belts.

may be

If

tension. Belt tension for a used belt

tfie belt

lbs. for all

a belt tension

except V4

gauge

is

in.

wide belts or

at

60

lbs. for

not available, the following proce-

used.

ADJUSTMENTS >

See Figures 64

thru

69

CAUTION may come on under certain circumstances, even though the ignition is OFF. Be sure to disconnect the negative battery cable before servicing your If

equipped, the electrically operated cooling fan

vehicle.

Alternator Belt Position a ruler perpendicular to the drive belt at

1

Test the tightness of the belt by pressing tion

should be between V4-^A6

2.

If

it

its

firmly with your

longest straight run.

thumb. The deflec-

(6-8mm).

the deflection exceeds these limits, loosen the alternator mounting and

adjusting 3.

in.

arm

Place a

bolts. 1

in.

(25mm) open-end

ridge cast on the body,

and

pull

or adjustable

on the wrench

wrench on the adjusting

until the

proper tension

is

achieved. 4.

arm

Holding the alternator

bolt.

Recheck the

in

place to maintain tension, tighten the adjusting

belt tension.

When

the belt

is

properly tensioned, tighten

the alternator mounting bolt.

Fig.

Fig.

64 Belt routing— 225 engine

65 318 and 360 engines

1-19

1-20

GENERAL INFORMATION AND MAINTENANCE Power Steering INLINE 6-CYLINDER ENGINES Hold a

1

ruler perpendicular to the drive belt at its longest run, test the

tightness ot the belt by pressing

be within Va

in,

(6mm), and

it

thumb. The deflection should

firmly with your

(8mm).

^/le in

To adjust the belt tension, loosen the adjusting and mounting bolts on

2.

the front face of the steering

pump

cover plate (hub side).

Using a large wooden dowel or a pry bar wrapped with a rag

3.

pump hub from damage, carefully pry on the hub in steering pump toward or away from the engine until Do

not pry against the reservoir as

DEFLECTION

is

and

relatively soft

the belt tension.

move

to protect the

the

power is

reached.

easily deformed.

pump in place, tighten the adjusting arm When the belt is properly tensioned tighten

Holding the

4.

1/4'

it

order to

the proper tension

and then recheck

bolt

the

mounting

bolts.

6-CYLINDER AND V8 ENGINES Position a ruler perpendicular to the drive belt at

1

1/2

DEFLECTION

tightness of the belt by pressing

be between Va-^As

loosen the three bolts

belt tension,

adjusting slots at the power steering Fig.

67 Checking

for

proper belt tension

pump

Turn the steering

3.

proper deflection

its

longest run. Test the

thumb. The deflection should

firmly with your

(6-8mm).

in.

To adjust the

2.

it

pump

in the three

elongated

attaching bracket.

drive bell adjusting nut as required until the

obtained. Turning the adjusting nut clockwise will increase

is

tension and decrease deflection; counterclockwise will decrease tension and increase deflection.

Without disturbing the pump, tighten the three attaching

4.

Compressor

Air Conditioning

Position a ruler perpendicular to the drive belt at

1

tightness of the belt by pressing

be between Va-^As 2.

If

bolts.

the engine

is

it

its

firmly with your thumb.

longest run. Test the

The deflection should

(6-8mm).

in.

equipped with an

idler

pulley loosen the idler pulley

adjusting bolt, insert a pry bar wrapped with a rag, between the pulley and the

engine (or If

to

in

the engine

3.

When

and adjust the tension accordingly.

the idler pulley adjusting slot), is

accomplish

moved

not equipped with an idler pulley the alternator must be

as outlined under Alternator

this adjustment,

the proper tension

bolt or the alternator adjusting

is

Belt.

reached, tighten the idler pulley adjusting

and mounting

bolts, as

equipped.

Pump

Air

Position a ruler perpendicular to the drive belt at

1

tightness of the belt by pressing

be between Va-^A6 2.

in.

To adjust the

firmly with your

its

longest run. Test the

thumb. The deflection should

(6-8mm).

belt tension,

sary also loosen the mounting 3.

it

loosen the adjusting arm bolt

slightly.

If

neces-

belt slightly.

Using a large wooden dowel or a pry bar wrapped with a rag to protect

pump from damage, carefully pry against the pump pump toward or away from the engine as necessary

rear cover to

the

move

the

CAUTION Do

not pry against the

ing

may

4.

pump housing

itself,

damage

as

to the

hous-

result.

Holding the

the tension.

When

pump

in place,

the belt

is

arm

tighten the adjusting

bolt

and recheck

properly tensioned, tighten the mounting bolt.

WARNING Check

to

make

sure that the V-ribbed belt

is

located properly in

all

drive pulleys before applying tensioner pressure.

REMOVAL & INSTALLATION t

See Figure 70 On most

the

Fig.

69 Then move the component or

obtain the proper tension and hold

it

idler pulley in the bracket to

while you tighten the bolt

vehicles, to

remove and

mounting bracket bolts

of the

with a towel or rag, carefully pry the

access

to slide the belt off

install

a

new

you

belt,

component Using a

component forward

and on. You may need

to

will

need

to

suitable pry tool

do

slightly to give

this

loosen

wrapped easy

an additional com-

GENERAL INFORMATION AND MAINTENANCE

1-21

Inspect the condition of the radiator and heater hoses periodically Early

spring and at the beginning of the

maintenance, are good times.

fall

t\/lake

or

mn[&. w/hen you

are performing other

sure the engine and cooling system are

cold. Visually inspect for cracking, rotting or collapsed hoses, replace as neces-

sary Run your hand along the length

of the

hose.

If

a

weak

or sw/ollen spot

is

noted when squeezing the hose wall, replace the hose.

REMOVAL & INSTALLATION t

See Figures 75 and 76 Drain the cooling system into a suitable container

1.

Fig.

70 Serpentine

ponent(s) few/ belts

you

in

make removal

order to

have

decide how/

to

remove the

many

When

draining the coolant, keep in mind that cats and dogs are

the container

is

be

to

is

of the radiator

clean) by loosening the draincock on the

CAUTION

or installation easier. if

Some models

you must replace

belt(s) that are in

belts require

the coolant

make sure

boltom

mounting

running different accessories,

«(ill first

first to

bell

(if

reused,

your

have a

and are quite likely to drink an uncovered container or in puddles on the in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

attracted by ethylene glycol antifreeze,

a belt in the rear,

my. Look

removal to access the belt

at

in

any that

your truck

need

is left in

ground. This will prove fatal

of

replacement.

Loosen the hose clamps

2.

at

each end

of the

hose

that requires replace-

ment. »

See Figures 71, 72, 73 and 74

Twist, pull

3.

and slide the hose

oft

the radiator, water

pump, thermostat

or

heater connection.

• CAUTION On models equipped with an

may come is

To

install:

Position the clamps on the

on,

OFF.

new hose.

Coat the connection surfaces with a water resistant sealer and slide the

6.

negative battery cable, or fan motor wiring harness connector

under certain circumstances, even though the ignition

Clean the hose mounting connections.

5.

electric cooling fan, disconnect the

before replacing any radiator/heater hose. The fan

4.

hose

into position. f\/lake sure the

bead

of the

connector

(if

hose clamps are located beyond the raised

equipped) and centered

in

the clamping area of the

connection.

TCCS1220

Fig. Fig. 71

The cracks developing along

hose are a result

of

this

age-related hardening

72 A hose clamp that

cause older hoses either side of the

is

too tight can

to separate

and tear on

clamp

TCCS1221

Fig.

73 A

soft

spongy hose (identifiable by

the swollen section) will eventually burst

and should be replaced

TCCS1222

Fig.

74 Hoses are

from the inside

if

86621303

Fig.

likely to deteriorate

the cooling system

periodically flushed

is

not

Fig.

75 Turn the radiator draincock to open

and drain the engine cooling system

76 Be CAREFUL

When

pulling hoses

from component necks as many of the connections are easily

damaged

GENERAL INFORMATION AND MAINTENANCE

1-22 7.

Tighten the clamps to

8.

Fill

9.

Start the

Check

20-30

inch lbs. (2-3 Nm).

Do

not overtighten,

the radiator cap and turn

while the pressure

the cooling system.

engine and allow

it

to

is

it

SLOWLY

to the first stop.

are sure the pressure has been released, press

reach normal operating temperature.

tor

for leaks.

cap

(still

Step back

When you

released from the cooling system.

have the cloth

in position) turn

down on

the radia-

and remove the radiator

cap.

Heat Riser INSPECTION SERVICING I I

See Figure 77

See Figures 79 and 80 At least

once every 2 years, the engine cooling system should be inspected,

flushed, and refilled with fresh coolant.

Every 30,000 miles (48,000 km), the heat riser valve should be checked for free operation

and then lubricated

«/ith

penetrating

oil.

The valve

is

with a

and

hammer

forth

it

it's

Apply penetrating

a few times.

and/or heat,

If

will

If

the valve

stuck, tap the

end

of the shaft a

The

few times belts

oil to is still

the shaft ends, then

it

loses

its

diluted with too

the exhaust manifold near the exhaust pipe attachment point. Try to turn the valve counterweight by hand.

long,

located on

work the valve back

stuck and can't be loosened with

oil

have to be replaced.

much water

it

radiator cap should be

should be inspected and,

is left in If

the system too

the coolant has been

won't protect against freezing.

examined if

for

signs of age or deterioration. Fan

necessary, adjusted to the proper tension

(please refer to Belt Tension Adjustment

Hose clamps should be

the coolant

If

and corrosion.

ability to prevent rust

tightened,

in this section).

and

soft or

cracked hoses replaced.

spots, or accumulations of rust or dye near hoses, the water areas, indicate possible leakage. This

pump

must be corrected before

Damp

or other

filling

the sys-

tem with fresh coolant.

GASKET

Fig.

77

Inline 6-cylinder manifold heat control valve

Fig.

79 Be sure the rubber gasket has a

tight seal

Cooling System >

See Figure 78

=•::•:

CAUTION

See Figures 84, 85 and 86 For

maximum

effectiveness and longest element

wiper blades should be kept clean.

used.

streaking, smearing

•

CARE & REPLACEMENT

lubricated.

In

order to prevent heater core freeze-up during A/C operation,

is

it

neces-

wash

and blade deterioration

life,

on the glass.

left

if

sary to maintain proper antifreeze protection. Be sure to properly maintain the

month. Wipe

engine cooling system,

move wipers across the windshield by hand; damage mechanism will result.

Any obstruction

• air

flow which

is

of or

damage

essential to

to the

condenser configuration

Keep

efficient operation.

its

will restrict

this unit clean

and

in

proper physical shape,

the condenser (unless they

in front of

LOW

speed position and the ignition switch

bottom

housing

of the evaporator

into the

engine compartment.

If

this tube is

torn, they

should

If

the glass, the elements should be replaced.

floor.

If

the wiper pattern

replace the elements

SYSTEM INSPECTION

your vehicle

If

types of

Although the A/C system should not be serviced by the do-it-yourselfer, sys-

cle's

A/C system. Be sure

The easiest and

often

to

to help

perform the following: tor the air conditioning

for refrigerant leaks,

damaged compressor

clutch,

A in

oily residue at the leakage point

and appears greasy. Through time,

air

be a heavy

dirt

this will build

up and appear

impregnated grease.

if

the blade chatters across

easiest and

most sensible

Check

the surface of the radiator

•

Check

•

IWake sure the drive belt

for kinks in

sure the belt

Make

is free of

hoses and

and condenser

is

refill

pushed

into place

refill

as the original equipment.

used, be sure to follow the part manufacturer's of the

all

and locked.

If

frame jaws are engaged as the

the metal blade holder

and frame are

will

be scratched.

to

sense and good driving habits

will afford

maximum

tire life.

tires. Either of

these

will

increase tread wear. Fast starts, sudden stops and

sharp cornering are hard on tire life,

often and have the

tires

and

keep the

will

shorten their useful

life

span.

tires properly inflated, rotate

wheel alignment checked

them

periodically.

Inspect your tires frequently. Be especially careful to watch for bubbles lines.

Check the system

from

all

make

the sidewall.

Any appropriate positions, then

cut

in

If

cuts are so deep that they penetrate to the cords, discard the

the sidewall of a radial

tread wear patterns that

may

tire

renders

indicate the front

it

is

out of alignment or that the

TCCS1223

84 Most aftermarket blades are avail-

able with multiple adapters to vehicles

fit

different

Fig.

85 Choose a blade which

will

fit

your

86

vehicle, and that will be readily available

Fig.

next time you need blades

blade

When

Is fully

tire.

unsafe. Also look tor uneven

end

tires are out of balance.

outlets.

the

in

tread or sidewall, deep cuts or underinflation. Replace any tires with bubbles in

for leaks.

noise or slippage. all

I^ake

sure that you don't overload the vehicle or run with incorrect pressure in the

for dirt, leaves or other

properly tensioned. During operation,

sure the blower motor operates at

for distribution of the air

Fig.

to

different

Tires and Wlieels

material which might block air flow,

check

is

It

vary with

equipped with aftermarket blades, there are several

of the type of

>»For optimum

For a thorough visual and operational inspection, check the following:

•

is

or streaked, or

use the exact same type blade or

Common appear as an

the system. The oily residue soon picks up dust or dirt particles from the sur-

•

smeared

will

about one

to

abnormal compressor

insulation,

refrigerant leak will usually

rounding

in

the

disconnected or broken wires, blown fuses, corroded connections

fins,

and poor

is

is

life

allowed to touch the glass during wiper operation, the glass

drive belt tension and/or condition, plugged evaporator drain tube, blocked con-

denser

When

and your vehicle might have any kind. Aftermarket blades and

refills

rarely

Regardless

refill

system

position.

in pairs.

instructions closely, fylake sure that

consists of a visual inspection of the system components. Visually inspect the

system

arms

maintain the efficiency of the vehi-

most important check

ACC

they are found to be cracked, broken or

year.

tem inspections should be performed

the

in

replaced immediately. Replacement intervals

tie

buildup can

over onto the vehicle's

not attempt to

motor and drive

to the

usage, although ozone deterioration usually limits element

obstructed, the air conditioning performance can be restricted and condensation spill

once a

OFF.

Examine the wiper blade elements.

The condensation drain tube expels any water which accumulates on the

•

Do

cause

advisable to

at least

wiper blades are approximately vertical on the windshield, turn the ignition switch to

are original equipment) are regarded as obstructions.

the rubber blades with the wet rag afterwards.

off

is

It

will

To inspect and/or replace the wiper blade elements, place the wiper switch the

>»Bug screens which are mounted

and so on

commercial glass cleaner

the windshield carefully with a

and

the windshield

sap, road tar

Dirt, tree

installed, be certain the

Inserted into the backing

GENERAL INFORMATION AND MAINTENANCE When

TIRE ROTATION to

I

See Figure 87 Tires

must be

position on

rotated periodically to equalize

Rotating

tfie tires will

not have to discard a rotation

is

When same

wear patterns

tire

ensure early

point wfiere

tfie

maximum

due

to

ttie

vary with a

ttiat

uneven way as

Tires will also wear in an

ttie vetiicle.

steering/suspension system wears to

ttie

reset.

means

that a tire

so you

will

When

part of the tread. Regular

make sure

that they

used on the

not be switched to the right side and vice-versa.

left

Such

always

roll in

side of the vehicle tires

on the same side

of

tion;

observe the marks when reinstalling the

Some

styled or

"mag" wheels may have

Snow

tire(s).

cases, the rear wheels must not be used up front and vice-versa. Furthermore,

unless the

tire is

remounted

for the

proper direction of rotation.

can produce a big advantage

radial tires

does not have

snow, a

street radial tire

control.

The small grooves

snow

specifications, regard-

tire

tire size

or brand,

body

of interference with the

remember

to

or suspension

Tires

Good

behaves