NOTE: BEFORE ATTEMPTING THIS RECALL, REVIEW VIP OR VEHICLE HISTORY TAB TO VERIFY THAT THE RECALL APPLIES TO THIS VEHICLE AND HAS NOT BEEN COMPLETED.

No. 605 May, 1994

To: All Dodge Truck Dealers

Subject: Safety Recall #605 -- Diesel

Models: This Service Requirement Applies to Both, Original Equipment and Warranty Replacement Fuel Injection on the Following Vehicles: • ORIGINAL EQUIPMENT PUMPS: -- Some Late 1991 Through Early 1992 Model Year Dodge Ram Pick Up Trucks (AD-body) Equipped With a 5.9L Intercooled Turbo (excluding warranty replacement pumps after May 11,1993) • WARRANTY SERVICE REPLACEMENT PUMPS: -- 1991, 1992 and 1993 Intercooled Turbo Diesel Engine and a Replacement Injection Pump Installed Through May 11, 1993

The fuel injection pump fulcrum lever pin may break causing a loss of control. To correct this condition, the fuel injection pump must be replaced.

IMPORTANT: Some of the involved vehicles may be in dealer inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery.

Details of this service action are explained in the following sections.

Service Procedure Videotape

As an additional service aid, a videotape demonstrating the service procedure will be included in the May, 1994 Master Tech program.

Dealer Notification & Vehicle List

Involved dealers: Each dealer to whom involved vehicles were invoiced (or the current dealer at the same street address) will receive a copy of this dealer recall notification letter and a list of the involved vehicles by Certified Mail.

Important: Dealer notification by Certified Mail is required by federal law for all safety recalls. Responsible dealership personnel should be instructed to sign for this Certified Mail without hesitation as it concerns urgent safety recall information.

The Vehicle List is arranged in Vehicle Identification Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer reference in arranging for service of involved vehicles. All dealers: Each Dodge Truck dealer will receive a copy of this dealer recall notification letter by first class mail.

DIAL System Function 70

All involved vehicles will be entered to DIAL System Function 70 at the time of recall implementation for dealer inquiry by VIN as needed.

Parts

Important: A quantity of parts will be distributed initially and billed (including core allowance) to all involved dealers. This quantity will cover a portion of the total vehicles involved. Additional parts will be supplied to all dealers as indicated in the Special Parts Supply Message with this recall notification letter.

Each involved dealer, to whom vehicles in the recall were invoiced (or the current dealer at the same street address), will receive enough Fuel Injection Pump Packages, PN C3906051 (Manual Transmission) andC3906052 (Automatic Transmission), to service 10% of those vehicles (minimum of 2 and maximum of 5 packages each).

Uninvolved dealers will not receive any packages initially.

Each parts package contains the following components:

Quantity Description 1 Pump, Diesel Fuel Injection (with 2 fuel outlet tube sealing washers) 1 Gasket, Pump Mounting 2 Washers, -To-Pump Supply Line Sealing 1 Sensor, Throttle Position (TPS) -- Automatic Transmission Package Only 1 Instruction Sheet

Owner Notification and Service Scheduling

All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for the service with their dealers at the earliest possible date. A copy of the owner notification letter is attached.

Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed.

Service Procedure

A. Fuel Injection Pump Date Code Inspection

Fuel injection pump replacement is only necessary for pumps manufactured between March and September, 1991 (date codes 163 through 169), that have not already been repaired for this condition. Pumps having an infinity symbol (¥) on either the pump data plate or the Mopar Remanufactured Parts data tag have alreadybeen repaired and therefore, do not require replacement. Suspect pumps may have been installed either during vehicle assembly or as a replacement (remanufactured) part.

1. Inspect the pump data plate for an infinity symbol (¥) as shown in Figure 1. Note: If a remanufactured pump has been installed, inspect the remanufactured parts data tag for an infinity symbol (¥) as shown in Figure 1.

If there IS an infinity symbol (¥) present on either the data plate or tag, no further action is required.

2. Inspect the pump data plate for date code 163, 164, 165, 166, 167, 168, or 169 (Figure 1).

Note: If a remanufactured pump has been installed, remove the top rivet and rotate the remanufactured parts data tag down to inspect the date code on the pump data plate below it.

B. Remove Fuel Injection Pump 1. With the ignition key in the OFF position, disconnect the battery.

Note: To ensure customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset the electronic memory when you have completed the service procedure.

2. Disconnect throttle linkage at the pump lever ball stud and remove the throttle linkage bracket and return springs (Figure 2).

Caution: Do not remove the pump control lever from the pump as it is indexed to the shaft during pump calibration.

3. Remove the air fuel control tube (Figure 3).

Caution: DO NOT bend any fuel tubes.

4. Remove the low pressure supply line from the pump and the separator filter (Figure 4). 5. Disconnect the fuel drain manifold and remove the hold-down clamp bolt located behind the high pressure lines (Figure 5). 6. Label and disconnect the electrical wires to the fuel shut off valve, KSB solenoid and for automatic transmission only, the .

Note: Two wires to fuel shut-off valve are interchangeable.

7. Disconnect the six high pressure lines at the rear of the pump using an injector fuel line crowfoot such as Mac #CHBM17, Matco #WCFS17M or Snap-On #FRHM17 (Figure 6).

Caution: Note each fuel line-to-pump outlet location to assure that the high pressure lines are installed onto the new pump properly.

8. Remove the oil dipstick and the top engine cover. Remove the four bracket bolts at the top of the manifold holding the two fuel bundles (Figure 7). 9. Disconnect the fuel tubes from the injectors using an injector fuel line socket such as Mac #COBR17, Matco #WCFM1517 or Snap-On #FRXM17. Remove the fuel line bundle for injectors 1, 2 and 3, then rotate the fuel bundle for injectors 4, 5 and 6 down to gain additional clearance at the rear of the pump (Figure 7). 10. Remove the top 2 bolts, and the bottom bolt, of the pump support bracket. Then loosen the remaining bolt (located behind the power steering pump) and swing bracket rearward (Figure 8). 11. Remove the oil filler bracket bolt and unscrew filler tube from base. Unscrew filler base from gear housing cover (Figure 9). 12. Remove pump drive gear retaining nut and washer (Figure 9).

Caution: Place towel under gear nut before removing it to make sure that nut, washer or drive key do not drop into gear housing.

13. Pull the fuel injection pump drive gear loose from the pump drive shaft using a T-bar puller such as Cummins #ST-647, Miller #L-4407A or Snap-On #CG606-BB (Figure 10). Remove T-bar puller from gear.

Note: Use 8mm x 1.25mm screws to attach puller to pump gear.

14. Remove the three pump-to-housing mounting nuts and remove the fuel injection pump from the mounting studs (Figure 11).

Note: Use an offset 13mm wrench to remove the lower inboard nut, such as Cummins #3377198 or Snap-On #SP144.

Caution: Use care when removing pump so that the drive key does not drop into the gear housing (Figure 11).

15. Remove the special washer wired to the replacement pump and set it aside for later use. Then transfer linkage ball stud on old pump throttle lever to the replacement pump throttle lever. 16. Vehicles equipped with automatic transmission only: Remove the three allen screws attaching the Throttle Position Sensor (TPS) and bracket assembly to the old injection pump top cover. Remove the old TPS from the bracket and save the TPS adapter, screws and bracket for installation onto the replacement injection pump (Figure 12 and Figure 13). 17. Set old pump aside to drain for a minimum of ten minutes, then plug all orifices. ALL PUMPSMUST BE RETURNED TO THE WARRANTY MATERIAL RETURN CENTER. Use the replacement pump packaging for return shipment. C. Install Replacement Fuel Injection Pump 1. Vehicles equipped with automatic transmission only: Remove the three top cover screws from the replacement pump and install them into the old pump (old pump allen screws are longer and required for the TPS bracket).

Install the TPS bracket onto the replacement pump using the allen screws from the old pump. Insert the hex on the bottom of the TPS adapter into the hex in the replacement pump throttle lever, making sure to engage the adapter tang into the notched area of the bracket (Figure 13). Install the provided TPS onto the bracket making sure to insert the slotted end of the TPS adapter into the notched area of the TPS.

The TPS adapter must engage the throttle lever hex and the TPS notch with the TPS and throttle levers spring loaded to the low idle position. (TPS will be adjusted after pump installation is complete).

2. Spray the Top Dead Center (TDC) lock pin with Mopar MP-50, PN 4549626, to assure proper operation. Push the pin in and pull it out several times until it moves freely (Figure 14). 3. Remove plastic plug at the lower right of transmission adapter housing and use a barring tool such as Cummins #3377371, Miller #7471A or Snap-On #SP371 to rotate engine in a clockwise direction (as viewed when facing the front of the engine) (Figure 14). Note: To rotate the engine in a clockwise direction, the barring tool must be rotated in a counter-clockwise direction as viewed from the front of the engine.

Locate the number one Top Dead Center (TDC) position of the compression by watching the key-way of the pump drive gear. Slowly rotate the engine and push in on the TDC lock pin when the drive gear key-way approaches the 6:00 position. The engine will be at TDC of the compression stroke when the lock pin engages the hole in the cam gear with the drive gear key-way at about the 5:30 position (Figures 14 & 15).

Caution: Rotate engine with a barring tool only. Do NOT use motor. STOP barring the engine IMMEDIATELY when the TDC lock pin "SNAPS" into the cam gear hole.

If the pump drive gear key-way passes the 4:30 position and the lock pin has not engaged the cam gear, rotate the engine counter-clockwise (rotate barring tool clockwise) to the 7:00 O'clock position and repeat this step. DO NOT ENGAGE THE LOCK PIN INTO THE CAM GEAR WHILE ROTATING THE ENGINE IN THE COUNTER-CLOCKWlSE DIRECTION AS PUMP-TO-ENGINE TIMING WILL BE AFFECTED.

4. Remove the barring tool, install the plastic plug into the access hole and pull the TDC lock pin out of the cam gear hole. DO NOT MOVE THE ENGINE ONCE THE NUMBER 1 TDC COMPRESSION STROKE POSITION IS SET.

Caution: Be sure to PULL TDC LOCK PIN OUT of cam gear or pin will be sheared off.

5. Remove the old injection pump mounting gasket. Clean the sealing surface and install the provided gasket (Figure 16). 6. Install the injection pump onto the mounting studs and finger tighten the three pump mounting nuts. The pump must be free to rotate in the slots (Figure 17). Make sure the key doesn't fall into the gear housing.

Caution: To prevent slippage, spray the pump drive shaft and drive gear with Mopar Brake Cleaner, PN 4318037, to assure both are clean and free of all oil before installation.

Note: The shaft of the replacement pump is locked so that the key aligns with the drive gear key-way when cylinder number one is at TDC of the compression stroke.

7. Install the pump drive gear nut and spring washer and torque to 18 ft-lbs (24 N•M). The pump may rotate slightly when tightening the pump drive nut because of the gear lash between the pump drive gear and cam gear. This movement is acceptable providing the entire pump moves within the mounting stud slots and there is no pump shaft-to-pump housing movement (Figure 18).

Caution: DO NOT OVER TIGHTEN PUMP DRIVE GEAR NUT. The replacement pump shaft is locked in position to eliminate the need to set pump-to- engine timing. This is NOT the final torque for the drive gear.

8. Gently rotate the against the direction of drive rotation to take up any gear lash as shown in figure 19. Evenly tighten the pump mounting stud nuts to 108 in-lbs (12N•M), then to a final torque of 18 ft-lbs (24 N•M).

Caution: DO NOT APPLY HEAVY ROTATIONAL FORCE on pump after gear backlash is removed as this may preload the pump and affect pump-to-engine timing.

9. Use a chisel or equivalent tool to permanently mark the injection pump mounting flange to match the existing mark on the gear housing (Figure 20). 10. Unlock the fuel injection pump shaft by loosening the lock screw as shown in figure 21. Insert the special washer (previously removed from the pump) under the lock screw, then torque the lock screw to 10 ft-Ibs (13 N•M). 11. Tighten the pump drive gear retaining nut to a final torque of 48 ft-lbs (65 N•M) as shown in figure 22. Remove towel previously placed in drive gear area. 12. Screw the oil filler base into the gear housing cover, then screw the filler tube into the base and tighten bracket bolt (Figure 9). 13. Install the fuel drain manifold (banjo) fitting to the pump using the new bolt and sealing washers provided with the replacement pump and torque bolt to 24 ft-lbs (32 N•M). Install the fuel tube hold-down clamp bolt and torque to 18 ft-lbs (24 N•M) (Figure 5).

Note: The new banjo bolt provided with the replacement pump has a calibrated bleed which is matched to the replacement pump. DO NOT reuse the old bolt or sealing washers.

14. Install the fuel supply line to the pump and torque fitting to 24 ft-lbs (32 N•M). Install the other end of the supply line to the separator filter using the new sealing washers provided. Leave this banjo bolt finger tight until after the fuel system has been purged of air (Figure 4). 15. Install the high pressure fuel lines to the pump and torque to 22 ft-lbs (30 N•M) (Figure 6). Install the fuel lines to each injector, but DO NOT tighten the fuel lines at the injectors until the fuel system has been purged of air.

Caution: Be sure that each fuel line is installed onto the same pump outlet port position from which it was removed. Prevent the injection pump delivery valve holders from turning when installing the lines onto the pump.

Note: THOROUGHLY clean the high pressure fuel lines with Mopar Brake Parts Cleaner, PN 4318037, to make sure NO debris is present before installing the fuel lines onto the injectors or fuel pump.

16. Coat the four bolts used to secure the fuel line support brackets with Mopar Silicone Sealer (RTV), PN 4318025, then install and torque the bolts to 18 ft-lbs (24 N•M) as shown in figure 7. Install the oil dipstick and top engine cover.

Note: Failure to apply sealant to the mounting bolts can result in an air intake leak.

17. Install the air fuel control tube (Figure 3). 18. Connect the electrical wires to the fuel shut off valve, KSB solenoid and for automatic transmission only, the throttle position sensor.

Note: Two wires to fuel shut-off valve are interchangeable.

19. Swing the pump support bracket into position and torque the 4 bolts to 18 ft-Ibs (24 N•M) (Figure 8). 20. Install the throttle bracket and torque bolts to 18 ft-lbs (24 N•M). Install throttle linkage onto pump lever ball stud and install the throttle return springs (Figure 2). 21. Inspect the closed throttle and wide open throttle accelerator linkage travel stops. Verify that the pump throttle lever contacts the low idle speed screw in the closed throttle position. With the aid of an assistant, depress accelerator pedal to the wide open throttle position. Verify that spring loaded breakover lever has moved off the stop and is against the break-over spring (Figure 23).

If the pump stops are not as described, adjust the linkage using the "Throttle Linkage Adjustment - Diesel Engine" procedure in the service manual.

22. Loosen the low pressure supply line banjo bolt and bleed screw at the separator filter and operate the hand lever on the lift pump until the fuel flowing from the fitting is free of air. Then torque the separator filter banjo bolt to 24 ft-Ibs (32 N•M) and the bleed screw to 72 in-lbs (8 N•M) (Figure 24). 23. Loosen all six fuel tube connections at the injectors and operate the hand lever of the lift pump until fuel is observed coming out one of the high pressure fuel lines at the injectors or until lift pump lever has been pumped a minimum of 30 seconds, whichever occurs first. (Figure 25). 24. Reconnect battery. 25. With the fuel tube connections still loose at all injectors and the transmission in neutral or park, crank the engine to allow entrapped air to bleed from the fuel lines (Figure 25). Tighten all injector fuel line connections.

Caution: The pressure of the fuel in the line is sufficient to penetrate the skin (59,000 kpa/8,000 psi) and cause serious bodily harm. Wear safety goggles and adequate protective clothing and do not allow contact with fuel spray when bleeding high pressure lines. Place the transmission in neutral or park and set the parking brake before engaging starter motor. When using the starter motor to purge air from the system, do not engage it for more than 30 seconds at a time and wait two minutes between engagements.

26. Start the engine and purge air from each injector fuel tube connection one line at a time until the engine runs smoothly (Figure 25). Tighten all injector fuel line connections to 18 ft-lbs (24 N•M) using an injector fuel line socket such as Mac #COBR17, Matco #WCFM1517 or Snap-On #FRXM17.

Caution: do not bleed air from the fuel system of a hot engine. Do not allow fuel to spray onto the when bleeding air from the fuel system.

27. Connect an optical tachometer to the engine such as Cummins #3377462, or Snap-On #MT139 (1992-93 models may use DRB II). Prepare the vehicle for an idle check as follows: „ apply parking brake, „ make sure throttle lever is against the low idle speed stop screw, „ turn the air conditioner ON, if equipped, „ bring the engine to full operating temperature. „ automatic transmission in drive, if equipped,

Check and adjust the engine low idle speed to 750 + 50 RPM, if necessary (Figure 26).

28. Vehicles equipped with automatic transmission only: Check and adjust the throttle position sensor (TPS) as follows (Figure 27): „ The injection pump throttle lever must be in the low idle position and the throttle lever must reach breakover when the throttle is wide open, turn the ignition key to the ON position, „ connect the negative lead of the voltmeter to a good ground (1991 1/2-93 models may use DRB II), „ insert the positive lead of the voltmeter to the center (output) wire of the TPS electrical connector (leave connector attached to TPS), „ with the throttle lever contacting the low idle screw, the TPS output voltage should be 1 volt ± 0.05 volt, „ adjust the closed throttle TPS setting, if required, by gently rotating the nylon adapter until the correct voltage is obtained „ open the throttle lever to the wide open position „ the TPS output voltage should increase a minimum of 2.25 volts from the closed throttle position voltage. „ if TPS required adjustment, disconnect the battery negative cable for 2 minutes to reset adaptive memory, then reconnect the battery

Completion Reporting and Reimbursement

Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments.

Use one of the following labor operation numbers and time allowances:

Labor Time Operation Number Allowance Inspect fuel injection pump 14605181 0.2 Hours Inspect and replace fuel injection pump--manual transmission 14605182 3.2 Hours vehicles Inspect and replace fuel injection pump --automatic transmission 14605183 3.3 Hours vehicles

Add the cost of the recall parts package plus applicable dealer allowance to your claim.

Note: For parts reimbursement, the core allowance must be subtracted from the C3906051 and C3906052 part numbers, and the net, less core value marked up. For core reimbursement, enter the corresponding core part number, U3906051 or U3906052, on the claim with NO MARK UP. The use of the special service labor operation numbers for cores is not permitted in the DIAL system for recalls.

Parts Return

ALL REMOVED FUEL INJECTION PUMPS MUST BE RETURNED TO THE WARRANTY MATERIAL RETURN CENTER (including dealers in Alaska and Hawaii). Drain the pump for approximately ten minutes and plug orifices. Use the replacement pump packaging and orifice plugs for return shipment.

Note: See Warranty Policy and Procedure Manual, Chapter 6, Subsection H for complete recall claim processing and material return instructions. Vehicle Not Available

If a vehicle is not available for service for a known reason, let us know by filling out the pre- addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the reason on a postcard and mail to:

Chrysler Corporation 429-10-04 P.O. Box 1919 Detroit, Michigan 48231-1919

Following the above procedures will expedite the processing of your claim.

If you have any questions or need assistance in completing this action, please contact your Zone Service Office.

Customer Services Field Operations Chrysler Corporation

SAFETY RECALL -- Diesel Fuel Injection Pump

Dear Chrysler Corporation Vehicle Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Chrysler Corporation has determined that a defect which relates to motor vehicle safety exists in some 1991, 1992 and 1993 model Dodge Ram Pick-up trucks equipped with a diesel engine. A pin inside the fuel injection pump may break. This may cause the engine fuel supply system to open to full throttle engine speed, which could result in an accident without prior warning.

Your vehicle, identified on the enclosed form, is affected. For this reason we ask that you arrange for service to correct the condition without delay. The service and required parts as described in this letter will be provided free of charge.

To correct the condition, your dealer will replace the fuel injection pump. The work will take about three and one-half hours to complete. However, additional time may be required depending on how dealer appointments are scheduled and processed To obtain this free service:

z Contact your dealer to schedule a service appointment. z Take the enclosed Owner Notification Form with you at the time of your appointment and give it to your dealer. The form identifies the vehicle and the service that is required.

If you have any problem obtaining the needed repair, please call the Chrysler Customer Center, toll free, at 1-800-853-1403. A representative will assist you in getting your vehicle repaired.

We regret any inconvenience which this action may cause you. However, we are concerned about your safety. If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call the Toll Free Auto Safety Hotline at 1 800-424-9393. (Washington D.C. area residents may call 366-0123.)

Thank you for your attention to this important matter.

Customer Services Field Operations Chrysler Corporation

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