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"97j8,. ; ;IIMPORT :ERVICE1 1.MANUAL· Volume -·· 1·.- - - -r-. - ---.lEngine, c:llassis & Body- ' . ---r-------'- --··---··--- ----------- - - ' - - - - -·- - - - : : . -. Jf., RAMRAIDEi d CHRYSLER. . . . . 1M 1;3T (l R S

SAFETY NOTICE:.CAUTIONALL SERVIC:I::. AND REBUILDING INSTRUCflONS CONTAINEQ H RE-IN ARE AP- .PLICABLE TQ, AND FOR THE CONVENIENCE OF, THE AUTOMOTIVE TRADEONLY. All test and repair procedures on components or assemblies in non automotive applications should be repaired in accordance with instructions supplied by the manufacturer of thetotal product.Proper service and repair is important to the safe, reliable, operation of all motor vehicles. Theservice procedures recommended and described in this publicaf were developed for professional service personnel and are effective methods for performing vehicle repair. Following theseprocedures will help assure efficient economical vehicle performance and service reliability.Some of these service procedures require the use of special tools designed for specific procedures. These special tools should be used when recommended throughout this publication.Special attention should be exercised when working with spring or tension loaded fasteners andaevices such as E-Ctips, Circlips, Snaprings etc. as careles·s removal can cause personal injury.AJ\\'ays wear safety goggles whenever working on vehicles or vehicle components . important to note that this publication contains various Cautions and Warnings. Theseu uld be carefully read in order to minimize the risk of personal injury , or the possibility that. .proper fervice m thods may damage the vehicle or render it unsafe. It is important to note. n se Cautions and Warnings cover only the situations and procedures Chrysler Motors has, ncountere and recommended. Chrysler Motors could not possibly know, evaluate, and advisethe service trade of all conceivable ways that service may be performed or of the possible hazardsof each. Consequently Chrysler Motors has not undertaken any such broad service review.Accordingly, anyone who uses a service procedure or tool that is not recommended in thispublication must assure oneself thoroughly that neither personal safety nor vehicle safety bejeopardized by the service methods they select. · t ,AS:CE.RTIFIEDWE SUPPORTVOLUNTARY TECHNICIANCERTIFICATION THROUGHINat onal lnst toJtt "'''i" 'tlSERVICE \ . }

. .GROUP INDEX1ervice ManualRA/f/1 RAIDERNOOAA·A Introduction andMaster TroubleshootingIILubrication and MaintenanceFront Suspension . . . . . .1987Volume-1Engine,Chassis & BodyFOREWORDThis Service Manual has been prepared with t helatest service information available at the time of "11ication.It is subdivided into va rious groupJgories and each section contains diagnosis.disassembly, repair, and installation proceduresalong with complete specif ications and tighteningreferences. Use of this manual will aid in properlyperforming ,any ser-Vicing necessary to maintain orrestore the high levels of performance and reliabilitydesigned into these outstanding vehicles.DRear Axle . . . . .Brakes- Serv ceParkmgClutch . . .Cooling . . .Engine . . . . . .Intake and Exhaust . .Body and Frame Alignment . .Fuel System . . :. . . . .Propeller Shaft and UniversalJointRear SuspensionPower Steering . . !\ : .*'.Transmission- Manual .Automatec. .·-··.· Wheels and TiresBody . . . .·d CHRYSLERY' IVIOTORSEmission Control SystemsNOTE" rysler Motors reserves the right to make changes in design or to·e additions to or improvements in i ts products without imposinga1, , ooligations upon itself to install them on its products previouslymanufactured.For Electrical, Heater &·Air-conditioning, refer to :.Volume-2"Electrical. Heater & Air-conditioning"m

2INTRODUCTION AND MASTER TROUBLESHOOTING- How To Use This ManualHOW TO USE THIS MANUALNOOBAAACONTENTSThe preceding page contains the GROUP INDEXwhich lists the group title and group number.PAGE NUMBERSAll page numbers consist of two sets of digitsseparated by a dash. The digits preceding the dashidentify the number of the group. The digits following the dash represent the consecutive pagenumber within the group. The page numbers canbe found on the top left or right of each page.Indicates incidental operationto be performed before removal or after installationTEXTUnless otherwise specified, each seNice procedurecovers all models. Procedures covering specificmodels are identified by the model codes, or sim ilardesignation (engine type, transmission type, etc.).A description .of these designations is covered inthis unit under "VEH ICLE IDENTIFICATION".-T ROUBLESHOOTINGTroubleshootings are classified into master troubleshooting and group troubleshooting and located asfollows:The master troubleshooting is prepared when thetrouble symptom relates to two or more groups andgiven in MASTER TROUBLESHOOTING.The group troubleshooting guide is prepared forcauses of problems related to that individual group only; a troubleshooting guide is prepared for eachappropriate group.Removal steps : The numbers before part namescorrespond to numbers in the illustration and indicate the order ofremoval.Disassembly steps : The numbers before partnames correspond to numbersin the illustration. and indicatethe order of disassembly .Installation steps : This is provided if installationcannot be made in the reverseorder of "Removal steps"; omitted if installation in the reverseorder of "Removal steps" ispossible.Reassembly steps : This is provided if reassemblycannot be made in the reverseorder of "Disassembly steps" ;omitted if reassembly in thereverse order of "Disassemblysteps" is possible.SERVICE PROCEDURESThe seNice steps are arranged in numerical orderand attentions to be paid in performing vehicle service are described in detail in SERVICE POINTS.DEFINITION OF TERMSSTANDARD VALUEIndicates the value used as the standard for judgingthe quality of a part or assembly on inspection or thevalue to which the part or assembly is corrected andadjusted. It is given by tolerance.LIMITShows the standard for jud ging the quality of a partor assembly on inspection and means the maximumor minimum value within which the part or assemblymust be kept functionally or in strength. It is a valueestablished outside the range of standard value.Classification ofSERVICE ROINTS : Removal : Installation : Disassembly : Reassemblyf.--/

INTRODUCTION AND MASTER TROUBLESHOOTING- How To Use This Manual3II'IIPage number7-10Group titleSection titleCOOLING - ThermostatTHERMOSTATIndicates tighteningtorqueREMOVAL AND INSTALLATIONPre-removal Operationof the Coolant (Reier to,.---'i -- .1 DrainingGROUP 0 LUBRICATION ANDM AINTENANCE - Maintenance Ser·vice.)Post-installation Operation Supplying of the Coolant (Refer to'--- - - t -1 GROUP 0 LUBRICATION ANDM AINTENANCE - Maintenance Service.)048 0 0 31Thermostat kitRepair kit or set parts areshown. (Only very f requentlyused parts are shown.)Indicatesnon-reusablepart.Removal steps1. Connection of water temperature switchconnec tor (Vehicles w ith an air conditioner)2. Connection of radiator upper hose3. Wa ter outlet filling4. Water outlet fitting gasket-:------ --- --- 5. ThermostatThis number corresponds tothe num ber in "Removalsteps", "Disassemblysteps", "Installation steps"or "Reassembly steps".NOTE(1) Reverse the removal procedures to reinstall.(2) : Refer to ·service Points of Installation''(3)Non-reusable pansm ·SERVICE POINTS OF INSTALLATION------ - --,5. INSTALLATION OF THERMOSTATInstall the t hermostat to the intake manif old as illustrated.CautionThe t hermostat flange fits over the manifold seat;ensure that the thermostat is not installed at an angle.I1An explanation of procedures. notes. etc.regard ing rem o val, installat ion. disassemblyand reassembly.

4INTRODUCTION AND MASTER TROUBLESHO,OTING- Vehicle IdentificationVEHICLE IDENTIFICATIONIVEHICLE IDENTIFICATION NUMBER LOCATIOI''The vehicle identification number {V.I.N.) is located on a k- eattached to the left top side of the instrument panel.-------------------;(I IIOOY552VEHICLE IDENTIFICATION CODE CHART PLATENOOCB·AAll vehicle identification numbers contain 17 digits. The vehiclenumber is a code which tells country. make. vehicle type. etc.JB4FJ43E1HJ0000011stdigitdigitCountry ersLinePriceclassFJ4High40011bs. RAMor more RAIDERwithhydrabrakesBodyEngine33-doormetaltop Truck9XNOTE* "Check digit" means a single number or letter X used to verify the accuracy of transcription of vehicle indentificationnumber.

5INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle IdentificationVEHICLE IDENTIFICATION NUMBER LISTFFOERAL.JIN (except sequence number)NOOCC-ABrandJB7FJ43E 0 HJEngine displacementDodgeRAM RAIDERJB7FJ43E 0 HJI2.555 liters(155.9 C.LD.)Model codeL042GTNJL2L042GTRJL2CALIFORNIA (Can also be sold in Federal states.)Eng ine displacementBrandVIN (except sequence number)JB7FJ43E 0 HJDodgeRAM RAIDERJB7FJ43E 0 HJ2.555 liters(155 .9C. I.D.)IiModel codeL042GTNJL7L042GTRJL7CANADAVIN (except sequence number)r-JB4FJ43E 0 HJJB4FJ43E 0 HJIBrandEngine displacement---4------------ DodgeI RAM2.5551itersModel codeL042GVNJL3I L042GVRJL3(155.9 C.I. D.)RAIDERIVEHICLE INFORMATION CODE PLATENOOCO·AVehicle information code plate is riveted on the headlight support panel in the engine compartment.The plate shows model code. engine model. transmissionmodel. and body color code.1.2.M ODELENGINE3. TRANSL042G VNJL2ILModel seriesVehicle modelG54BI tEngine modelKM 145AXLE0I NOINI!Trans mission modelT"AM &AJ.l(C:OlOfi,Tf'llllon4. COLOR. TRIM 876OPT - - rMontone exteriorcolor codeOOK520B07B76H43L '-----Two-tone color codeExterior codeTwo-tone exterior is shown by theexterio r code fo ll owed by the twocolor codes.

6INTRODUCTION AND MASTER TROUBLESHOOTING- Vehicle IdentificationCHASSIS NUMBERSTAMPING LOCATIONThe chassis number is stamped on the side of the frame .the right rear shock absorber.CHASSIS NUMBER CODE CHARTL042-- /Vehicle line-L04RAMRAIDERV HJ000001 Eng inedisplacement-22.555 liters(155.9 C. I. D.)Body type-V- 3-doormetal-topT-VanRefer to 1Oththru 17th digitsof V.I.N. plateVEHICLE SAFETY CERTIFICATION LABELNOOCf-The vehicle safety certification label is attached to face of leftdoor pillar.This label indicates the month and year of manufacture, GrVehicle Weight Rating (G.V.W.R.). front and rear Gross A.Weight Rating (G.A.W.R.), and Vehicle Identification Number(V.I.N.).JENGINE MODEL STAMPINGNOOCG··The engine model number is stamped at the right front side onthe top edge of the cylinder block as shown in the following:Engine modelEngine displacementG54B2.5551iters (155.9 C.I. D.)The engine serial number is stamped near the engine modelnumber. and the serial number cycles, as shown below.Engine serial numberNumber cyclingAA020 1 to YY9999AA0201--- [AB0001--- AY9999[BA0001-- - YY9999AA9999 IJ

INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle IdentificationBODY COLOR CODENOOCH·AExterior codeBody colorMonotoneB767Dark blue (Metallic)H43Silver (Metallic)K78Gold ilver (Metallic)/Dark blue (Metallic)H63 H43X15Black/Silver (Metallic)R02 R52 H43Silver (Metallic)/RedX97 X15 K78Black/Gold (Metallic)