Cooling wiring DODGE RAM 1500 1998 2.G User Guide

(3) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(4) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(5) Connect both battery cables.
(6) Start and warm the engine. Check for leaks.
WATER PUMP - 5.7L
REMOVAL
(1) Disconnect negative battery cable.
(2) Drain coolant.
(3) Remove serpentine belt.
(4) Remove fan clutch assembly.
(5) Remove coolant fill bottle.
(6) Disconnect washer bottle wiring and hose.
(7) Remove fan shroud assembly.
(8) Remove A/C compressor and generator brace.
(9) Remove idler pulleys.
(10) Remove belt tensioner assembly.
(11) Remove upper and lower radiator hoses.
(12) Remove heater hoses.
(13) Remove water pump mounting bolts and
remove pump.
INSTALLATION
(1) Install water pump and mounting bolts.
Tighten moubting bolts to 24 N´m (18 ft. lbs.).
(2) Install heater hoses.
(3) Install upper and lower radiator hoses.
(4) Install belt tensioner assembly.
(5) Install idler pulleys.
(6) Install A/C compressor and alternator brace.
Tighten bolt and nuts to 28 N´m (21 ft. lbs.).
(7) Install fan shroud assembly.
(8) Connect washer bottle wiring and hose.
(9) Install coolant fill bottle.
(10) Install fan clutch assembly.
(11) Install serpentine belt.
(12) Connect negative battery cable.
(13) Fill coolant.
(14) Pressure test coolant system
WATER PUMP - 8.0L
DIAGNOSIS AND TESTING - WATER PUMP
A quick test to determine if pump is working is to
check if heater warms properly. A defective water
pump will not be able to circulate heated coolant
through the long heater hose to the heater core.
Fig. 49 Water Pump Removal/Installation
1 - O-RING SEAL (SQUARE)
2 - WATER PUMP
3 - BOLT (2)
Fig. 50 Pump O-ring Seal
1 - O-RING SEAL
2 - GROOVE
3 - WATER PUMP
DRENGINE 7 - 63
WATER PUMP - 5.9L DIESEL (Continued)

is secured by integral mounting tabs and a snap fea-
ture to slots in the right side of the cooling module
shroud in the engine compartment. On models with
an optional diesel engine, the washer reservoir is
secured by screws to the back of the upright left ver-
tical member of the radiator support in the engine
compartment. The washer reservoir filler neck is
accessed from the engine compartment.
²Wiper Arm- The two wiper arms are secured
with integral latches to the serrated ends of the two
wiper pivot shafts, which extend through the cowl
plenum cover/grille panel located near the base of the
windshield.
²Wiper Blade- The two wiper blades are
secured to the two wiper arms with an integral latch,
and are parked on the glass near the bottom of the
windshield when the wiper system is not in opera-
tion.
²Wiper High/Low Relay- The wiper high/low
relay is an International Standards Organization
(ISO) micro relay located in the Integrated Power
Module (IPM) in the engine compartment near the
battery.
²Wiper Module- The wiper pivot shafts are the
only visible components of the wiper module. The
remainder of the module is concealed within the cowl
plenum area beneath the cowl plenum cover/grille
panel. The wiper module includes the wiper module
bracket, four rubber-isolated wiper module mounts,
the wiper motor, the wiper motor crank arm, the two
wiper drive links, and the two wiper pivots.
²Wiper On/Off Relay- The wiper on/off relay is
an International Standards Organization (ISO) micro
relay located in the Integrated Power Module (IPM)
in the engine compartment near the battery.
Hard wired circuitry connects the wiper and
washer system components to the electrical system of
the vehicle. These hard wired circuits are integral to
several wire harnesses, which are routed throughout
the vehicle and retained by many different methods.
These circuits may be connected to each other, to the
vehicle electrical system and to the wiper and washer
system components through the use of a combination
of soldered splices, splice block connectors, and many
different types of wire harness terminal connectors
and insulators. Refer to the appropriate wiring infor-
mation. The wiring information includes wiring dia-
grams, proper wire and connector repair procedures,
further details on wire harness routing and reten-
tion, as well as pin-out and location views for the
various wire harness connectors, splices and grounds.
OPERATING MODES
The components of the wiper and washer system
are designed to work in concert to provide the follow-
ing operating modes:²Continuous Wipe Mode- The control knob on
the control stalk of the multi-function switch has two
continuous wipe positions, Low and High. When
selected, these switch positions will cause the two-
speed wiper motor to operate in a continuous low or
high speed cycle.
²Intermittent Wipe Mode- The control knob on
the control stalk of the multi-function switch has five
minor detent intermittent wipe positions. When
selected, these switch positions will cause the wiper
system to operate with one of five delay intervals
between complete wipe cycles. The intermittent wipe
delay intervals are speed sensitive and will be dou-
bled when the vehicle speed is about sixteen kilome-
ters-per-hour (ten miles-per-hour) or less.
²Pulse Wipe Mode- When the control knob on
the control stalk of the multi-function switch is
depressed to the momentary Wash position for less
than about one-half second, the wiper system will
operate the wipers for one complete low speed cycle,
then will park the wiper blades near the base of the
windshield.
²Washer Mode- When the control knob on the
control stalk of the multi-function switch is
depressed to the momentary Wash position for more
than about one-half second with the wiper system
turned Off, the washer pump/motor and the wipers
will operate for as long as the washer switch is held
closed up to about thirty seconds, then the wipe-af-
ter-wash mode is invoked when the control knob is
released. When the Wash position is selected with
the wiper system operating in a continuous wipe
mode, washer fluid will be dispensed onto the wind-
shield glass through the washer nozzles for as long
as the washer switch is held closed up to about thirty
seconds. When the Wash position is selected with the
wiper system operating in an intermittent wipe
mode, washer fluid is still dispensed until the control
knob is released; however, the wipers will operate in
a low speed continuous cycle from the time the
washer switch is closed until several wipe cycles
after the switch is released, before returning to the
selected intermittent wipe interval. If the control
knob is held in the depressed Wash position for more
than about thirty seconds, washer system operation
will be suspended until the control knob is released
for about two seconds then cycled back to the Wash
position.
²Wipe-After-Wash Mode- When the control
knob on the control stalk of the multi-function switch
is depressed to the momentary Wash position for
more than about one-half second with the wiper sys-
tem turned Off, the washer pump/motor and the wip-
ers will operate for as long as the washer switch is
held closed up to about thirty seconds, then provide
several additional wipe cycles after the control knob
DRWIPERS/WASHERS 8R - 3
WIPERS/WASHERS (Continued)

(12) Disconnect heater hoses from heater core and
remove hose assembly.
(13) Disconnect throttle and speed control cables.
(14) Remove upper radiator hose from engine.
(15) Remove lower radiator hose from engine.
(16) Remove radiator/cooling module assembly.
(17) Disconnect the engine to body ground straps
at the left side of cowl.
(18) Disconnect the engine wiring harness at the
following points:
²Intake air temperature (IAT) sensor
²Fuel Injectors
²Throttle Position (TPS) Switch
²Idle Air Control (IAC) Motor
²Engine Oil Pressure Switch
²Engine Coolant Temperature (ECT) Sensor
²Manifold Absolute Pressure MAP) Sensor
²Camshaft Position (CMP) Sensor
²Coil Over Plugs
²Crankshaft Position Sensor
(19) Remove coil over plugs.
(20) Release fuel rail pressure.
(21) Remove fuel rail and secure away from
engine.
NOTE: It is not necessary to release the quick con-
nect fitting from the fuel supply line for engine
removal.
(22) Remove the PCV hose.
(23) Remove the breather hoses.
(24) Remove the vacuum hose for the power brake
booster.
(25) Disconnect knock sensors.
(26) Remove engine oil dipstick tube.
(27) Remove intake manifold.
(28) Install engine lifting fixture,special tool#8247,
using original fasteners from the removed intake
manifold, and fuel rail. Torque to factory specifica-
tions.
NOTE: Recheck bolt torque for engine lift plate
before removing engine.
(29) Secure the left and right engine wiring har-
nesses away from engine.
(30) Raise vehicle.
(31) Disconnect oxygen sensor wiring.
(32) Disconnect crankshaft postion sensor.
(33) Disconnect the engine block heater power
cable, if equipped.
(34) Disconnect the front propshaft at the front
differential and secure out of way.
NOTE: It is necessary to disconnect the front prop-
shaft for access to the starter and left side exhaust
flange.(35) Remove the starter.
(36) Remove the ground straps from the left and
right side of the block.
(37) Disconnect the right and left exhaust pipes at
the manifolds and from the crossover, and remove
from the vehicle.
NOTE: The exhaust clamps at the manifolds cannot
be reused. New clamps must be used or leaks may
occur.
(38) Remove the structural cover.
(39) Remove torque convertor bolts, and mark
location for reassembly.
(40) Remove transmission bellhousing to engine
bolts.
(41) Remove left and right engine mount thru
bolts.
(42) Lower the vehicle.
(43) Support the transmission with a suitable jack.
(44) Connect a suitable engine hoist to the engine
lift plate.
(45) Remove engine from vehicle.
INSTALLATION
(1) Position the engine in the vehicle.
(2) Install both left and right side engine mounts
onto engine.
(3) Raise the vehicle.
(4) Install the transmission bellhousing to engine
mounting bolts. Tighten the bolts to 41 N´m (30ft.
lbs.).
(5) Tighten the engine mount thru bolts.
(6) Install the torque convertor bolts.
(7) Connect the ground straps on the left and right
side of the engine.
(8) Install the starter.
(9) Connect the crankshaft position sensor.
(10) Install the engine block heater power cable, if
equipped.
CAUTION: The structural cover requires a specific
torque sequence. Failure to follow this sequence
may cause severe damage to the cover.
(11) Install the structural cover.
NOTE: New clamps must be used on exhaust man-
ifold flanges. Failure to use new clamps may result
in exhaust leaks.
(12) Install the left and right exhaust pipes.
(13) Connect the left and right oxygen sensors.
(14) Lower vehicle.
(15) Remove the engine lift plate.
(16) Connect the knock sensors.
DRENGINE - 3.7L 9 - 11
ENGINE - 3.7L (Continued)

(17) Connect the engine to body ground straps at
the left side of the cowl.
(18) Install the intake manifold.
(19) Install the engine oil dipstick tube.
(20) Install the power brake booster vacuum hose.
(21) Install the breather hoses.
(22) Install the PCV hose.
(23) Install the fuel rail.
(24) Install the coil over plugs.
(25) Connect the engine wiring harness at the fol-
lowing points:
²Intake air temperature (IAT) sensor
²Fuel Injectors
²Throttle Position (TPS) Switch
²Idle Air Control (IAC) Motor
²Engine Oil Pressure Switch
²Engine Coolant Temperature (ECT) Sensor
²Manifold Absolute Pressure MAP) Sensor
²Camshaft Position (CMP) Sensor
²Coil Over Plugs
²Crankshaft Position Sensor
(26) Reinstall the radiator/cooling module assem-
bly.
(27) Connect lower radiator hose.
(28) Connect upper radiator hose.
(29) Connect throttle and speed control cables.
(30) Install the heater hose assembly.
(31) Install coolant recovery bottle.
(32) Install the power steering pump.
(33) Install the generator.
(34) Install the A/C compressor.
(35) Install the drive belt.
(36) Install the fan shroud with the viscous fan
assembly.
(37) Install the radiator core support bracket.
(38) Install the air cleaner assembly.
(39) Refill the engine cooling system.
(40) Recharge the air conditioning.
(41) Install the hood.
(42) Check and fill engine oil.
(43) Connect the battery negative cable.
(44) Start the engine and check for leaks.SPECIFICATIONS
SPECIFICATIONS - 3.7L ENGINE
GENERAL SPECIFICATIONS
DESCRIPTION SPECIFICATION
Type 90É SOHC V6 12 Valve
Number of
Cylinders4
Firing Order 1-6-5-4-3-2
Lead Cylinder No. 1 Left Bank
Compression
Ratio9.1:1
Max. Variation
Between
Cylinders25%
Metric Standard
Displacement 3.7 Liters 226 Cubic
Inches
Bore 93.0 mm 3.66 in.
Stroke 90.8 mm 3.40 in.
Horsepower 210@5200 RPM
Torque 225ft. lbs.@4200 PRM
Compression
Pressure1172-1551 kPa 170-225 psi
CYLINDER BLOCK
DESCRIPTION SPECIFICATION
Metric Standard
Bore Diameter 93.0   .0075
mm3.6619   0.0003
in.
Out of Round
(MAX)0.076 mm 0.003 in.
Taper (MAX) 0.051 mm 0.002 in.
9 - 12 ENGINE - 3.7LDR
ENGINE - 3.7L (Continued)

Position both the left and right side engine mount
brackets and install the through bolts and nuts.
Tighten nuts to4X2 vehicles95 N´m (70 ft. lbs.).
4X4 vehicles102 N´m (75 ft. lbs.).
(2)4X4 vehiclesInstall locknuts onto the engine
mount brackets. Tighten locknuts to 41 N´m (30 ft.
lbs.).
(3) Remove jack from under the transmission.
(4) Remove Engine Lifting Fixture Special Tool
8347 (Fig. 4).
(5) Remove Special Tools 8400 Lifting Studs.
(6) Position generator wiring behind the oil dip-
stick tube, then install the oil dipstick tube upper
mounting bolt.
(7) Connect both left and right side body ground
straps.
(8) Install power steering pump.
(9) Connect fuel supply line quick connect fitting
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
QUICK CONNECT FITTING - STANDARD PROCE-
DURE).
(10) Connect the vacuum lines at the throttle body
and intake manifold.
(11) Connect engine harness at the following
points (Fig. 3):
²Intake Air Temperature (IAT) Sensor
²Idle Air Control (IAC) Motor
²Fuel Injectors
²Throttle Position (TPS) Switch
²Engine Oil Pressure Switch
²Engine Coolant Temperature (ECT) Sensor
²Manifold Absolute Pressure (MAP) Sensor
²Camshaft Position (CMP) Sensor
²Coil Over Plugs
(12) Position and install heater hoses and tubes
onto intake manifold.
(13) Install the heater hoses onto the heater core
and the engine front cover.
(14) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(15) Install A/C condenser (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/A/C CON-
DENSER - INSTALLATION), radiator (Refer to 7 -
COOLING/ENGINE/RADIATOR - INSTALLATION)
and transmission oil cooler.
(16) Connect radiator upper and lower hoses.
(17) Connect the transmission oil cooler lines to
the radiator.
(18) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -INSTALLATION), fan assembly and shroud (Refer to
7 - COOLING/ENGINE/FAN DRIVE VISCOUS
CLUTCH - INSTALLATION).
(19) Install A/C compressor (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/A/C COM-
PRESSOR - INSTALLATION).
(20) Install both breathers. Connect tube to both
crankcase breathers (Fig. 2).
(21) Connect throttle and speed control cables.
(22) Install throttle body resonator assembly and
air inlet hose. Tighten clamps 4 N´m (35 in. lbs.).
(23) Raise vehicle.
(24) Install transmission to engine mounting bolts.
Tighten the bolts to 41 N´m (30 ft. lbs.).
(25) Install torque converter bolts (Automatic
Transmission Only).
(26) Connect crankshaft position sensor (Fig. 1).
(27)4X4 vehiclesPosition and install the axle
isolator bracket onto the axle, transmission and
engine block. Tighten bolts to specification (Refer to 9
- ENGINE - SPECIFICATIONS).
(28) Install starter (Refer to 8 - ELECTRICAL/
STARTING/STARTER MOTOR - INSTALLATION).
CAUTION: The structural cover requires a specific
torque sequence. Failure to follow this sequence
may cause severe damage to the cover.
(29) Install structural cover (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER - INSTAL-
LATION).
(30) Install exhaust crossover pipe.
(31) Install engine block heater power cable, If
equipped.
(32)4X4 vehiclesConnect axle vent tube to left
side engine mount.
(33) Lower vehicle.
(34) Check and fill engine oil.
(35) Recharge the A/C system (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/REFRIG-
ERANT - STANDARD PROCEDURE).
(36) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(37) Install the battery tray and battery.
(38) Connect the battery positive and negative
cables.
(39) Start the engine and check for leaks.
9 - 98 ENGINE - 4.7LDR
ENGINE - 4.7L (Continued)

(13) Install the cooling fan (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION).
(14) Connect battery negative cables.
(15) Start engine and check for oil leaks.
INTAKE MANIFOLD
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the charge air cooler outlet tube from
the air inlet housing (Fig. 118).
(3) Remove the engine oil dipstick tube mounting
bolt (Fig. 118).
(4) Remove dipstick support at fuel filter housing.
Position dipstick tube to the side.
(5) Disconnect the air grid heater power cables at
the cable mounting studs.
(6) Disconnect the ground strap at the intake
cover.
(7) Remove the engine wiring harness connections
at the air inlet housing elbow.
(8) Remove the four (4) air inlet housing mounting
bolts and remove the housing from top of the heater
elements.
(9) Remove the intake air grid heater from the
manifold (Fig. 119).
(10) Remove the high pressure fuel lines and fuel
rail (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL LINES - REMOVAL).
(11) Remove APPS bracket from cylinder head to
gain access to front intake manifold cover bolts.
(12) Disconnect manifold air temperature/pressure
sensor connector.
(13) Remove the remaining intake manifold cover-
to-cylinder head bolts.
(14) Remove the intake manifold cover and gasket.
Keep the gasket material and any other material out
of the air intake.
(15) Clean the intake manifold cover and cylinder
head sealing surface.
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Clean cylinder block gasket surfaces using a suit-
able solvent.
The plenum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.
Fig. 118 Charge Air Cooler Air Tube
1 - FRONT WIRING CLIP
2 - GROUND CABLE
3 - TUBE BOLT
4 - ENGINE OIL DIPSTICK TUBE
5 - CLAMPS
6 - AIR TUBE (INT. MAN.-TO-INTERCOOLER)
7 - RUBBER HOSE
8 - AIR INTAKE HOUSING
9 - CABLE BRACKET HOUSING
Fig. 119 Intake Air Grid Heater
1 - INTAKE AIR GRID HEATER
2 - GASKET
DRENGINE 5.9L DIESEL 9 - 297
OIL PUMP (Continued)

and coil are the only serviced parts on the compres-
sor.
A/C compressor clutch engagement is controlled by
several components: the A/C-heater control, A/C pres-
sure transducer, A/C compressor clutch relay, evapo-
rator temperature sensor and the powertrain control
module (PCM). The PCM may delay compressor
clutch engagement for up to thirty seconds (Refer to
8 - ELECTRICAL/ELECTRONIC CONTROL MOD-
ULES/POWERTRAIN CONTROL MODULE -
DESCRIPTION).
DIAGNOSIS AND TESTING - A/C COMPRESSOR
CLUTCH COIL
For circuit descriptions and diagrams, (Refer to
Appropriate Wiring Information). The battery must
be fully-charged before performing the following
tests. Refer to Battery for more information.
(1) Connect an ammeter (0 to 10 ampere scale) in
series with the clutch coil terminal. Use a voltmeter
(0 to 20 volt scale) with clip-type leads for measuring
the voltage across the battery and the compressor
clutch coil.
(2) With the A/C-heater controls in any A/C mode,
and the blower motor switch in the lowest speed
position, start the engine and run it at normal idle.
(3) The compressor clutch coil voltage should read
within 0.2 volts of the battery voltage. If there is
voltage at the clutch coil, but the reading is not
within 0.2 volts of the battery voltage, test the clutch
coil feed circuit for excessive voltage drop and repair
as required. If there is no voltage reading at the
clutch coil, use a DRB IIItscan tool and (Refer to
Appropriate Diagnostic Information) for testing of thecompressor clutch circuit and PCM control. The fol-
lowing components must be checked and repaired as
required before you can complete testing of the clutch
coil:
²Fuses in the junction block and the power distri-
bution center (PDC)
²A/C-heater control
²A/C compressor clutch relay
²A/C pressure transducer
²Evaporator temperature sensor
²Powertrain control module (PCM)
(4) The compressor clutch coil is acceptable if the
current draw measured at the clutch coil is within
specifications with the electrical system voltage at
11.5 to 12.5 volts (Refer to 24 - HEATING & AIR
CONDITIONING - SPECIFICATIONS). This should
only be checked with the work area temperature at
21É C (70É F). If system voltage is more than 12.5
volts, add electrical loads by turning on electrical
accessories until the system voltage drops below 12.5
volts.
(a) If the clutch coil current reading is above
specifications, the coil is shorted and should be
replaced.
(b) If the clutch coil current reading is zero, the
coil is open and should be replaced.
STANDARD PROCEDURE - A/C COMPRESSOR
CLUTCH BREAK-IN
After a new compressor clutch has been installed,
cycle the compressor clutch approximately twenty
times (five seconds on, then five seconds off). During
this procedure, set the A/C-heater control to the
Recirculation Mode, the blower motor switch in the
highest speed position, and the engine speed at 1500
to 2000 rpm. This procedure (burnishing) will seat
the opposing friction surfaces and provide a higher
compressor clutch torque capability.
REMOVAL
The refrigerant system can remain fully-charged
during compressor clutch, rotor, or coil replacement.
The compressor clutch can be serviced in the vehicle.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the serpentine drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Disconnect the compressor clutch coil wire har-
ness connector.
(4) Remove the bolts that secure the compressor to
the mounting bracket.
(5) Remove the compressor from the mounting
bracket. Support the compressor in the engine com-
partment while servicing the clutch.
Fig. 1 Compressor Clutch - Typical
1 - CLUTCH PLATE
2 - SHAFT KEY (not used on KJ)
3 - ROTOR
4 - COIL
5 - CLUTCH SHIMS
6 - SNAP RING
7 - SNAP RING
24 - 10 CONTROLSDR
A/C COMPRESSOR CLUTCH/COIL (Continued)

ING/CONTROLS/BLOWER MOTOR RESISTOR
BLOCK - INSTALLATION).
(5) If removed, install the blower motor (Refer to
24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION/BLOWER MOTOR - INSTALLATION).
(6) Install the HVAC wire harness. Make sure the
wires are routed through all wiring retainers.
(7) Connect the wire harness to the blower motor,
blower motor resistor block, evaporator temperature
sensor and each actuator.
(8) Install the HVAC housing (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION).
INSTALLATION
WARNING: IF THE VEHICLE IS EQUIPPED WITH AIR
CONDITIONING, REVIEW THE WARNINGS AND
CAUTIONS IN PLUMBING BEFORE PERFORMING
THE FOLLOWING OPERATION. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - WARNING)
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - CAUTION) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION -
REFRIGERANT HOSES/LINES/TUBES PRECAU-
TIONS)
(1) Position the HVAC housing into the vehicle. Be
certain that the evaporator condensate drain tube
and the housing mounting studs are inserted into
their correct locations.
(2) Install the two nuts that secure the HVAC
housing to the mounting studs in the passenger com-
partment. Tighten the nuts to 6.2 N´m (55 in. lbs.).
(3) Install the bolt that secures the HVAC housing
to the floor bracket in the passenger compartment.
Tighten the bolt to 6.2 N´m (55 in. lbs.).
(4) Install the instrument panel (Refer to 23 -
BODY/INSTRUMENT PANEL - INSTALLATION).
(5) Install the two nuts that secure the HVAC
housing to the mounting studs in the engine com-
partment. Tighten the nuts to 6.2 N´m (55 in. lbs.).
(6) Install the powertrain control module (PCM)
(Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/POWERTRAIN CONTROL MOD-
ULE - INSTALLATION).
(7) Unplug or remove the tape from the heater
core tubes and connect the heater hoses to the heater
core tubes.
(8) Unplug or remove the tape from the opened
refrigerant line fittings and the evaporator outlet
tube and install the accumulator (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/AC-
CUMULATOR - INSTALLATION).
(9) Unplug or remove the tape from the liquid line
and the evaporator inlet tube fittings. Connect the
liquid line coupler to the evaporator inlet tube (Referto 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE - A/C LINE COU-
PLERS).
(10) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(11) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
(12) Fill the engine cooling system (Refer to 7 -
COOLING/ENGINE - STANDARD PROCEDURE).
(13) Connect the battery negative cable.
(14) Start the engine and check for proper opera-
tion of the heating and air conditioning systems.
INSTRUMENT PANEL
DEMISTER DUCTS
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the defroster ducts (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
DEFROSTER DUCTS - REMOVAL).
(2) Remove the two screws that secure the center
distribution duct to the instrument panel support.
(3) Remove the center distribution duct from
instrument panel support, panel ducts and demister
ducts.
(4) Remove the right side panel duct adapter (Fig.
11).
(5) Remove the right side intermediate demister
duct.
(6) Remove the left side intermediate demister
duct.
(7) Remove the left side panel duct adapter.
(8) Remove the instrument panel cover (Refer to
23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - REMOVAL).
24 - 36 DISTRIBUTIONDR
HVAC HOUSING (Continued)

DEPLOYMENT - STANDARD
PROCEDURE, SERVICE AFTER A
SUPPLEMENTAL RESTRAINT............8O-7
DETECTION ASSY - DESCRIPTION,
NATURAL VAC LEAK..................25-23
DETECTION ASSY - INSTALLATION,
NATURAL VAC LEAK..................25-25
DETECTION ASSY - OPERATION,
NATURAL VAC LEAK..................25-23
DETECTION ASSY - REMOVAL, NATURAL
VAC LEAK..........................25-24
DETECTION PUMP - DESCRIPTION, LEAK . 25-13
DETECTION PUMP - INSTALLATION,
LEAK..............................25-16
DETECTION PUMP - OPERATION, LEAK . . . 25-14
DETECTION PUMP - REMOVAL, LEAK....25-16
DEVICES - STANDARD PROCEDURE,
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE........................8W-01-8
DIAGNOSTIC TROUBLE CODES -
DESCRIPTION........................25-1
DIAGNOSTICS (OBD) - DIAGNOSIS AND
TESTING, ON-BOARD...................7-5
DIAGRAMS - DESCRIPTION, HOW TO
USE WIRING......................8W-01-1
DIAGRAMS - HYDRAULIC SCHEMATICS,
SCHEMATICS.................21-176,21-337
DIESEL - CLEANING, RADIATOR - 5.9L....7-56
DIESEL - CLEANING, RADIATOR FAN -
5.9L................................7-35
DIESEL - CLEANING, WATER PUMP -
5.9L................................7-62
DIESEL - DESCRIPTION.................14-62
DIESEL - DESCRIPTION, 5.9L............11-3
DIESEL - DESCRIPTION, BELT
TENSIONER - 5.9L.....................7-23
DIESEL - DESCRIPTION, COOLING
SYSTEM FLOW - 5.9L...................7-3
DIESEL - DESCRIPTION, ENGINE 5.9L....9-232
DIESEL - DESCRIPTION, ENGINE BLOCK
HEATER - 5.9L........................7-37
DIESEL - DESCRIPTION, ENGINE
COOLANT THERMOSTAT - 5.9L...........7-46
DIESEL - DESCRIPTION, FAN DRIVE
VISCOUS CLUTCH - 5.9L...............7-52
DIESEL - DESCRIPTION, RADIATOR -
5.9L................................7-56
DIESEL - DESCRIPTION, TRANS COOLER
- 5.9L..............................7-68
DIESEL - DESCRIPTION, WATER PUMP -
5.9L................................7-62
DIESEL - FUEL INJECTOR FIRING ORDER . 14-48
DIESEL - INSPECTION, RADIATOR - 5.9L . . . 7-56
DIESEL - INSPECTION, RADIATOR FAN -
5.9L................................7-35
DIESEL - INSPECTION, TAILPIPE - 5.9L . . . 11-10
DIESEL - INSPECTION, WATER PUMP -
5.9L................................7-62
DIESEL - INSTALLATION................11-8
DIESEL - INSTALLATION...............14-62
DIESEL - INSTALLATION.....19-26,19-31,19-42
DIESEL - INSTALLATION, BELT
TENSIONER - 5.9L.....................7-24
DIESEL - INSTALLATION, DRIVE BELT -
5.9L
................................7-29
DIESEL - INSTALLATION, ENGINE BLOCK
HEATER - 5.9L
........................7-38
DIESEL - INSTALLATION, ENGINE
COOLANT THERMOSTAT - 5.9L
...........7-47
DIESEL - INSTALLATION, EXCEPT
........14-19
DIESEL - INSTALLATION, MUFFLER -
5.9L
...............................11-10
DIESEL - INSTALLATION, RADIATOR -
5.9L
................................7-57
DIESEL - INSTALLATION, RADIATOR FAN
- 5.9L
..............................7-36
DIESEL - INSTALLATION, TAILPIPE - 5.9L
. 11-11
DIESEL - INSTALLATION, WATER PUMP -
5.9L
................................7-62
DIESEL - MAINTENANCE SCHEDULES,
24-VALVE CUMMINS TURBO
.............0-12
DIESEL - OPERATION, BELT TENSIONER
- 5.9L
..............................7-23
DIESEL - OPERATION, ENGINE BLOCK
HEATER - 5.9L
........................7-38
DIESEL - OPERATION, ENGINE COOLANT
THERMOSTAT - 5.9L
...................7-46DIESEL - OPERATION, FAN DRIVE
VISCOUS CLUTCH - 5.9L...............7-52
DIESEL - OPERATION, RADIATOR - 5.9L . . . 7-56
DIESEL - OPERATION, TRANS COOLER -
5.9L................................7-69
DIESEL - OPERATION, WATER PUMP -
5.9L................................7-62
DIESEL - REMOVAL....................11-7
DIESEL - REMOVAL...................14-62
DIESEL - REMOVAL.........19-25,19-30,19-41
DIESEL - REMOVAL, BELT TENSIONER -
5.9L................................7-23
DIESEL - REMOVAL, DRIVE BELT - 5.9L....7-29
DIESEL - REMOVAL, ENGINE BLOCK
HEATER - 5.9L........................7-38
DIESEL - REMOVAL, ENGINE COOLANT
THERMOSTAT - 5.9L...................7-47
DIESEL - REMOVAL, EXCEPT...........14-17
DIESEL - REMOVAL, MUFFLER - 5.9L.....11-10
DIESEL - REMOVAL, RADIATOR - 5.9L.....7-56
DIESEL - REMOVAL, RADIATOR FAN -
5.9L................................7-35
DIESEL - REMOVAL, TAILPIPE - 5.9L.....11-10
DIESEL - REMOVAL, WATER PUMP -
5.9L................................7-62
DIESEL - SPECIFICATIONS, 5.9L.........9-244
DIESEL - TORQUE, FUEL SYSTEM -
EXCEPT.............................14-3
DIESEL ENGINE - DESCRIPTION, FUEL
REQUIREMENTS.......................0-1
DIESEL ENGINE - DIAGNOSIS AND
TESTING............................11-5
DIESEL ENGINE - DIAGNOSIS AND
TESTING, COOLING SYSTEM.............7-7
DIESEL ENGINE - INSTALLATION........8R-17
DIESEL ENGINE - INSTALLATION, 5.9L . . . 24-54,
24-58,24-72
DIESEL ENGINE - INSTALLATION,
EXCEPT............................8R-17
DIESEL ENGINE - REMOVAL............8R-16
DIESEL ENGINE - REMOVAL, 5.9L . . 24-53,24-56,
24-70
DIESEL ENGINE - REMOVAL, EXCEPT....8R-15
DIESEL ENGINE - STANDARD
PROCEDURE, DRAINING COOLING
SYSTEM 5.9L........................7-18
DIESEL ENGINE - STANDARD
PROCEDURE, REFILLING COOLING
SYSTEM 5.9L........................7-19
DIESEL ENGINE - TORQUE, FUEL
SYSTEM............................14-48
DIESEL ENGINE, SPECIAL TOOLS - 5.9L . . 9-246
DIESEL ENGINES - DESCRIPTION,
ENGINE OIL...........................0-2
DIESEL FUEL SYSTEM - DESCRIPTION . . . 14-45
DIESEL FUEL SYSTEM, SPECIAL TOOLS . . 14-49
DIESEL ONLY - ASSEMBLY, 5.9L..........7-70
DIESEL ONLY - DISASSEMBLY, 5.9L.......7-70
DIFFERENTIAL - ASSEMBLY . . . 3-129,3-156,3-47,
3-73,3-99
DIFFERENTIAL - DISASSEMBLY....3-128,3-155,
3-47,3-72,3-98
DIFFERENTIAL - INSTALLATION....3-130,3-157,
3-48,3-74,3-99
DIFFERENTIAL - REMOVAL
. . . 3-127,3-155,3-46,
3-72,3-97
DIFFERENTIAL CASE BEARINGS -
INSTALLATION
....3-106,3-134,3-161,3-48,3-75
DIFFERENTIAL CASE BEARINGS -
REMOVAL
........3-105,3-134,3-161,3-48,3-75
DIFFERENTIAL COVER - INSTALLATION
....3-97
DIFFERENTIAL COVER - REMOVAL
........3-97
DIFFERENTIAL TRAC-RITE - ASSEMBLY
. . 3-133,
3-161
DIFFERENTIAL TRAC-RITE - CLEANING
. . . 3-132,
3-160
DIFFERENTIAL TRAC-RITE -
DESCRIPTION
..................3-131,3-158
DIFFERENTIAL TRAC-RITE -
DISASSEMBLY
..................3-131,3-158
DIFFERENTIAL TRAC-RITE - INSPECTION
. 3-132,
3-160
DIFFERENTIAL TRAC-RITE - OPERATION
. . 3-131,
3-158
DIFFERENTIAL-TRAC-LOK - ASSEMBLY
. . . 3-103
DIFFERENTIAL-TRAC-LOK -
DESCRIPTION
.......................3-100DIFFERENTIAL-TRAC-LOK - DIAGNOSIS
AND TESTING.......................3-100
DIFFERENTIAL-TRAC-LOK -
DISASSEMBLY.......................3-101
DIFFERENTIAL-TRAC-LOK - OPERATION . . . 3-100
DIMENSIONS - SPECIFICATIONS, BODY
OPENING...........................23-99
DIMENSIONS - SPECIFICATIONS, FRAME . . 13-16
DIODE - INSTALLATION............8W-01-14
DIODE - REMOVAL................8W-01-14
DIODE REPLACEMENT - STANDARD
PROCEDURE........................24-45
DISC - INSTALLATION, CLUTCH...........6-5
DISC - REMOVAL, CLUTCH...............6-5
DISC BRAKE CALIPER ADAPTER MOUNT
- INSTALLATION......................5-22
DISC BRAKE CALIPERS - DESCRIPTION....5-16
DISC BRAKE CALIPERS - OPERATION.....5-16
DISC BRAKE ROTOR, DIAGNOSIS AND
TESTING............................5-32
DISCHARGE (ESD) SENSITIVE DEVICES -
STANDARD PROCEDURE,
ELECTROSTATIC...................8W-01-8
DISCHARGE LINE - DESCRIPTION, A/C....24-56
DISPLAY TEST MODE - DESCRIPTION,
STATE ..............................25-1
DISTRIBUTION - DESCRIPTION, POWER . 8W-97-1
DISTRIBUTION - OPERATION, POWER . . 8W-97-1
DISTRIBUTION DUCT - INSTALLATION,
FLOOR.............................24-34
DISTRIBUTION DUCT - REMOVAL,
FLOOR.............................24-33
DISTRIBUTION SYSTEMS, SPECIAL
TOOLS - POWER...................8W-97-2
DOME LAMP - DESCRIPTION...........8L-26
DOME LAMP - INSTALLATION..........8L-26
DOME LAMP - OPERATION.............8L-26
DOME LAMP - REMOVAL..............8L-26
DOOR - INSTALLATION...........23-18,23-28
DOOR - INSTALLATION, BLEND.........24-27
DOOR - INSTALLATION, DEFROST.......24-31
DOOR - INSTALLATION, FUEL FILL.......23-39
DOOR - INSTALLATION, MODE..........24-38
DOOR - INSTALLATION, RECIRCULATION . . 24-40
DOOR - REMOVAL...............23-18,23-28
DOOR - REMOVAL, BLEND.............24-27
DOOR - REMOVAL, DEFROST...........24-31
DOOR - REMOVAL, FUEL FILL..........23-39
DOOR - REMOVAL, MODE..............24-38
DOOR - REMOVAL, RECIRCULATION.....24-39
DOOR ACTUATOR - DESCRIPTION,
BLEND.............................24-17
DOOR ACTUATOR - DESCRIPTION,
DEFROST...........................24-20
DOOR ACTUATOR - DESCRIPTION,
MODE.............................24-23
DOOR ACTUATOR - DESCRIPTION,
RECIRCULATION.....................24-24
DOOR ACTUATOR - INSTALLATION,
BLEND.............................24-18
DOOR ACTUATOR - INSTALLATION,
DEFROST...........................24-21
DOOR ACTUATOR - INSTALLATION,
MODE.............................24-23
DOOR ACTUATOR - INSTALLATION,
RECIRCULATION.....................24-25
DOOR ACTUATOR - OPERATION, BLEND . . 24-17
DOOR ACTUATOR - OPERATION,
DEFROST...........................24-21
DOOR ACTUATOR - OPERATION, MODE . . . 24-23
DOOR ACTUATOR - OPERATION,
RECIRCULATION
.....................24-24
DOOR ACTUATOR - REMOVAL, BLEND
....24-17
DOOR ACTUATOR - REMOVAL, DEFROST
. . 24-21
DOOR ACTUATOR - REMOVAL, MODE
....24-23
DOOR ACTUATOR - REMOVAL,
RECIRCULATION
.....................24-24
DOOR AJAR INDICATOR - DESCRIPTION
. . 8J-23
DOOR AJAR INDICATOR - OPERATION
....8J-23
DOOR AJAR SWITCH - DESCRIPTION
....8L-27
DOOR AJAR SWITCH - OPERATION
......8L-27
DOOR GLASS - INSTALLATION
.....23-20,23-30
DOOR GLASS - REMOVAL
........23-20,23-30
DOOR GLASS RUN WEATHERSTRIP -
INSTALLATION, FRONT
................23-92
DOOR GLASS RUN WEATHERSTRIP -
INSTALLATION, REAR
.................23-93
10 INDEXDR
Description Group-Page Description Group-Page Description Group-Page