DODGE 1995 Van 6L 2500 Repair Notes

Posted: July 11, 2012 in Uncategorized
Tags: , , , ,

COMMON QUESTIONS:

Problem: Engine is cutting out. There is a “hick up” during idle.

Q: How do you trouble shoot?

A: Run engine low on fuel then add a fuel treatment and fresh high octane fuel. Check performance. Check distributor cap, spark plugs and wires. Check performance. Test Vacuum pressure. Check air lines. Test the Brake Booster.

 

Q:How do you identify a bad distributor, cap, wire and/or plug?
A: Start the engine. Wear thick gloves & tighten one plug wire connection at a time. IF the engine performance increases, you may just have a loose wire connection. IF a plug wire vrefuses to shock or spark as you move the plug wire end around the cap or plug, turn off the power and examine the cap connections and the spark plug as needed.

 

Q: How do you check vacuum pressure?

A: Remove the cap on the back of brake booster T/elbow and connect a vacuum pressure gauge. OEM manual reports that a healthy pressure should maintain at 22-25 iHM.

Q: What do you check if you have a low iHM vacuum reading?

A: Your brake booster may be failing.

 

Q: How do you test your brake booster?

A: Look for visual clues like corrosion and cracks. Low vacuum pressure? Failing or sporadic power steering?

 

Q: How do you test power steering pump vs. brake booster for sporadic steering troubles?

A:

 

Q: How do you identify if you have a worn valve?

A:

 

Q: How do you identify if the head/s are damaged or just a gasket is cracked?

A: Compression test.

 

Q: How do you do a compression test?

A:

 

Q: What is the difference between a compression test for a damaged head vs. a worn valve?

A:

 

NOTES: Clear and rust coat the undercarriage near the AC drip line. This spot is known to rust out the idler arm.

 

MANUALs:

2004+ are free at http://www.dodge.com/en/owners/manuals/

<2004

Donate $5 to our Charity and I’ll get you a ZIP file with the full manual or just the pages you need to view offline.

Go here: https://elibrary.mel.org/validate?url=http%3A%2F%2F0-infotrac.galegroup.com.elibrary.mel.org%3A80%2Fitweb%2Flom_accessmich%3Fdb%3DCHLL

In the top box enter B12 and then any other 10 numbers, then click the login button, This will bring you to an online Chilton's manual. You might have to try a couple of times. When you get the pages you want, download/print them out for convenience in case you can't access the site when you really need to.

Check the AUTOZONE archives: http://www.autozone.com/autozone/repairinfo/repairInfoLanding.jsp?UseCase=L001&UserAction=viewHomePage

 

RESOURCES:

DodgeForm.com ; peachparts.com ; http://www.youtube.com/watch?v=X_tbksFYhl4&feature=related ;

CarTalk.com ; CarAndTruckTalk.com ; EricTheCarGuy.com

 

PARTS:

Car-Stuff.com

Oreillys.com ( http://tinyurl.com/7zp7sct )

 

TOOLS:

Compression Checker

 

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

INSTALLING NEW VALVES?

Before disassembling the cylinder head, you may want to fabricate some containers to hold the various parts, as some of them can be quite small (such as keepers) and easily lost. Also keeping yourself and the components organized will aid in assembly and reduce confusion. Where possible, try to maintain a components original location; this is especially important if there is not going to be any machine work performed on the components.

  1. If you haven’t already removed the rocker arms and/or shafts, do so now.
  2. Position the head so that the springs are easily accessed.
When removing an OHV valve spring, use a compressor tool to relieve the tension from the retainer

When removing an OHV valve spring, use a compressor tool to relieve the tension from the retainer
Click to Enlarge
  1. Use a valve spring compressor tool, and relieve spring tension from the retainer.

Due to engine varnish, the retainer may stick to the valve locks. A gentle tap with a hammer may help to break it loose.

A small magnet will help in removal of the valve locks

A small magnet will help in removal of the valve locks
Click to Enlarge
Be careful not to lose the small valve locks (keepers)

Be careful not to lose the small valve locks (keepers)
Click to Enlarge
  1. Remove the valve locks from the valve tip and/or retainer. A small magnet may help in removing the locks.
  2. Lift the valve spring, tool and all, off of the valve stem.
Remove the valve seal from the valve stem-O-ring type seal shown

Remove the valve seal from the valve stem-O-ring type seal shown
Click to Enlarge
Removing an umbrella/positive type seal

Removing an umbrella/positive type seal
Click to Enlarge
  1. If equipped, remove the valve seal. If the seal is difficult to remove with the valve in place, try removing the valve first, then the seal. Follow the steps below for valve removal.
Invert the cylinder head and withdraw the valve from the valve guide bore

Invert the cylinder head and withdraw the valve from the valve guide bore
Click to Enlarge
  1. Position the head to allow access for withdrawing the valve.

Cylinder heads that have seen a lot of miles and/or abuse may have mushroomed the valve lock grove and/or tip, causing difficulty in removal of the valve. If this has happened, use a metal file to carefully remove the high spots around the lock grooves and/or tip. Only file it enough to allow removal.

  1. Remove the valve from the cylinder head.
  2. If equipped, remove the valve spring shim. A small magnetic tool or screwdriver will aid in removal.
  3. Repeat Steps 3 though 9 until all of the valves have been removed.
IF valves/springs were removed do the following to re-install…
  1. Lightly lubricate the valve stems and insert all of the valves into the cylinder head. If possible, maintain their original locations.
  2. If equipped, install any valve spring shims which were removed.
  3. If equipped, install the new valve seals, keeping the following in mind:
    • If the valve seal presses over the guide, lightly lubricate the outer guide surfaces.
    • If the seal is an O-ring type, it is installed just after compressing the spring but before the valve locks.
  4. Place the valve spring and retainer over the stem.
  5. Position the spring compressor tool and compress the spring.
  6. Assemble the valve locks to the stem.
  7. Relieve the spring pressure slowly and insure that neither valve lock becomes dislodged by the retainer.
  8. Remove the spring compressor tool.
  9. Repeat Steps 2 through 8 until all of the springs have been installed.

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

 

 

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