valve cover DODGE RAM 1500 1998 2.G User Guide

(2) Apply a small amount of engine oil to sensor
o-ring.
(3) Install sensor into cylinder head with a slight
rocking action. Do not twist sensor into position as
damage to o-ring may result.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to timing chain
cover. If sensor is not flush, damage to sensor
mounting tang may result.
(4) Install mounting bolt and tighten. Refer to
Torque Specifications.
(5) Connect electrical connector to sensor.
5.9L Diesel
The CMP is located on the back of the timing gear
cover (Fig. 14).
(1) Clean out machined hole in back of timing gear
cover.
(2) Apply a small amount of engine oil to sensor
o-ring.
(3) Install sensor into timing gear cover with a
slight rocking action. Do not twist sensor into posi-
tion as damage to o-ring may result.
CAUTION: Before tightening sensor mounting bolt,
be sure sensor is completely flush to back of timing
chain cover. If sensor is not flush, damage to sen-
sor mounting tang may result.
(4) Install mounting bolt and tighten. Refer to
Torque Specifications.
(5) Connect electrical connector to sensor.
IGNITION COIL
DESCRIPTION
3.7L V-6
The 3.7L V-6 engine uses 6 dedicated, and individ-
ually fired coil for each spark plug (Fig. 15). Each
coil is mounted directly into the cylinder head and
onto the top of each spark plug (Fig. 16).
4.7L V-8
The 4.7L V±8 engine uses 8 dedicated, and individ-
ually fired coil (Fig. 15) for each spark plug. Each
coil is mounted directly to the top of each spark plug
(Fig. 17).
5.7L V-8
The 5.7L V±8 engine uses 8 dedicated, and individ-
ually fired coil (Fig. 18) for each pair of spark plugs.
Each coil is mounted directly to the top of each spark
plug (Fig. 19). Each coil is bolted to the valve cover.
Fig. 15 IGNITION COIL - 3.7L V-6/ 4.7L V-8
1 - O-RING
2 - IGNITION COIL
3 - ELECTRICAL CONNECTOR
Fig. 16 IGNITION COIL LOCATION - 3.7L V-6
1 - IGNITION COIL
2 - COIL MOUNTING NUT
DRIGNITION CONTROL 8I - 11
CAMSHAFT POSITION SENSOR (Continued)

(4) Remove coil mounting nut from mounting stud
(Fig. 17).
(5) Carefully pull up coil from cylinder head open-
ing with a slight twisting action.
(6) Remove coil from vehicle.
5.7L V-8
Before removing or disconnecting any spark plug
cables, note their original position. Remove cables
one-at-a-time. To prevent ignition crossfire, spark
plug cablesMUSTbe placed in cable tray (routing
loom) into their original position.
An individual ignition coil (Fig. 18) is used at each
cylinder. The coil mounts to the top of the valve cover
with 2 bolts (Fig. 19). The bottom of the coil is
equipped with a rubber boot to seal the spark plug to
the coil. Inside each rubber boot is a spring. The
spring is used for a mechanical contact between the
coil and the top of the spark plug.
(1) Depending on which coil is being removed, the
throttle body air intake tube or intake box may need
to be removed to gain access to coil.
(2) Unlock electrical connector (Fig. 19) by moving
slide lock first. Press on release lock (Fig. 19) while
pulling electrical connector from coil.
(3) Disconnect secondary high-voltage cable from
coil with a twisting action.
(4) Clean area at base of coil with compressed air
before removal.
(5) Remove 2 mounting bolts (note that mounting
bolts are retained to coil).
(6) Carefully pull up coil from cylinder head open-
ing with a slight twisting action.
(7) Remove coil from vehicle.
(8) Before installing spark plug cables to either the
spark plugs or coils, or before installing a coil to a
spark plug, apply dielectric grease to inside of boots.
INSTALLATION
3.7L V-6
(1) Using compressed air, blow out any dirt or con-
taminants from around top of spark plug.
(2) Check condition of coil o-ring and replace as
necessary. To aid in coil installation, apply silicone to
coil o-ring.
(3) Position ignition coil into cylinder head opening
and push onto spark plug. Do this while guiding coil
base over mounting stud.
(4) Install coil mounting stud nut. Refer to torque
specifications.
(5) Connect electrical connector to coil by snapping
into position.
(6) If necessary, install throttle body air tube.
4.7L V-8
(1) Using compressed air, blow out any dirt or con-
taminants from around top of spark plug.
(2) Check condition of coil o-ring and replace as
necessary. To aid in coil installation, apply silicone to
coil o-ring.
(3) Position ignition coil into cylinder head opening
and push onto spark plug. Do this while guiding coil
base over mounting stud.
(4) Install coil mounting stud nut. Refer to torque
specifications.
(5) Connect electrical connector to coil by snapping
into position.
(6) If necessary, install throttle body air tube.
5.7L V-8
(1) Using compressed air, blow out any dirt or con-
taminants from around top of spark plug.
(2) Before installing spark plug cables to either the
spark plugs or coils, or before installing a coil to a
spark plug, apply dielectric grease to inside of boots.
(3) Position ignition coil into cylinder head opening
and push onto spark plug. Twist coil into position.
(4) Install 2 coil mounting bolts. Refer to torque
specifications.
(5) Connect electrical connector to coil by snapping
into position.
(6) Install cable to coil. To prevent ignition cross-
fire, spark plug cablesMUSTbe placed in cable tray
(routing loom) into their original position. Refer to
Spark Plug Cable Removal for a graphic.
(7) If necessary, install throttle body air tube.
KNOCK SENSOR
DESCRIPTION
The sensors are used only with 3.7L V-6, 4.7L V-8
and 5.7L V-8 engines. On 3.7L V-6 and 4.7L V-8
engines, the 2 knock sensors are bolted into the cyl-
inder block under the intake manifold.
On 5.7L V-8 engines, 2 knock sensors are also
used. These are bolted into each side of the cylinder
block (outside) under the exhaust manifold.
OPERATION
3.7L V-6 / 4.7L V-8 / 5.7L V-8 Engines Only
Two knock sensors are used; one for each cylinder
bank. When the knock sensor detects a knock in one
of the cylinders on the corresponding bank, it sends
an input signal to the Powertrain Control Module
(PCM). In response, the PCM retards ignition timing
for all cylinders by a scheduled amount.
8I - 14 IGNITION CONTROLDR
IGNITION COIL (Continued)

5.9L Diesel With Manual Trans.
The speed control system is fully electronically con-
trolled by the Engine Control Module (ECM).A
cable and a vacuum controlled servo are not
used if the vehicle is equipped with a manual
transmission and a diesel engine. This is a ser-
vo-less system.The controls consist of two steering
wheel mounted switches. The switches are labeled:
ON/OFF, RES/ACCEL, SET, COAST, and CANCEL.
The system is designed to operate at speeds above
30 mph (50 km/h).
WARNING: THE USE OF SPEED CONTROL IS NOT
RECOMMENDED WHEN DRIVING CONDITIONS DO
NOT PERMIT MAINTAINING A CONSTANT SPEED,
SUCH AS IN HEAVY TRAFFIC OR ON ROADS THAT
ARE WINDING, ICY, SNOW COVERED, OR SLIP-
PERY.
OPERATION
When speed control is selected by depressing the
ON switch, the PCM (the ECM with a diesel engine)
allows a set speed to be stored in its RAM for speed
control. To store a set speed, depress the SET switch
while the vehicle is moving at a speed between 35
and 85 mph. In order for the speed control to engage,
the brakes cannot be applied, nor can the gear selec-
tor be indicating the transmission is in Park or Neu-
tral.
The speed control can be disengaged manually by:
²Stepping on the brake pedal
²Depressing the OFF switch
²Depressing the CANCEL switch.
²Depressing the clutch pedal (if equipped).
NOTE: Depressing the OFF switch or turning off the
ignition switch will erase the set speed stored in
the PCM (the ECM with a diesel engine).
For added safety, the speed control system is pro-
grammed to disengage for any of the following condi-
tions:
²An indication of Park or Neutral
²A rapid increase rpm (indicates that the clutch
has been disengaged)
²Excessive engine rpm (indicates that the trans-
mission may be in a low gear)
²The speed signal increases at a rate of 10 mph
per second (indicates that the coefficient of friction
between the road surface and tires is extremely low)
²The speed signal decreases at a rate of 10 mph
per second (indicates that the vehicle may have
decelerated at an extremely high rate)Once the speed control has been disengaged,
depressing the RES/ACCEL switch (when speed is
greater than 30 mph) restores the vehicle to the tar-
get speed that was stored in the PCM (the ECM with
a diesel engine).
While the speed control is engaged, the driver can
increase the vehicle speed by depressing the RES/AC-
CEL switch. The new target speed is stored in the
PCM (the ECM with a diesel engine) when the RES/
ACCEL is released. The PCM (the ECM with a diesel
engine) also has a9tap-up9feature in which vehicle
speed increases at a rate of approximately 2 mph for
each momentary switch activation of the RES/AC-
CEL switch.
A ªtap downº feature is used to decelerate without
disengaging the speed control system. To decelerate
from an existing recorded target speed, momentarily
depress the COAST switch. For each switch activa-
tion, speed will be lowered approximately 1 mph.DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - VACUUM SUPPLY
TEST
3.7L / 4.7L Gas Powered Engines
3.7L/4.7L gas powered engines: actual engine vac-
uum, a vacuum reservoir, a one-way check valve and
vacuum lines are used to supply vacuum to the speed
control servo.
(1) Disconnect vacuum hose at speed control servo
and install a vacuum gauge into the disconnected
hose.
(2) Start engine and observe gauge at idle. Vac-
uum gauge should read at least ten inches of mer-
cury.
(3) If vacuum is less than ten inches of mercury,
determine source of leak. Check vacuum line to
engine for leaks. Also check actual engine intake
manifold vacuum. If manifold vacuum does not meet
this requirement, check for poor engine performance
and repair as necessary.
(4) If vacuum line to engine is not leaking, check
for leak at vacuum reservoir. To locate and gain
access to reservoir, refer to Vacuum Reservoir Remov-
al/Installation in this group. Disconnect vacuum line
at reservoir and connect a hand-operated vacuum
pump to reservoir fitting. Apply vacuum. Reservoir
vacuum should not bleed off. If vacuum is being lost,
replace reservoir.
8P - 2 SPEED CONTROLDR
SPEED CONTROL (Continued)

CABLE
DESCRIPTION
The speed control servo cable is connected between
the speed control vacuum servo diaphragm and the
throttle body control linkage. This cable is used with
3.7L/4.7L gas powered engines only. It is also used if
equipped with a 5.9L diesel engine equipped with an
automatic transmission.
A speed control servo cableis not usedif equipped
with either a 5.9L diesel engine equipped with a
manual transmission, or any 5.7L engine/transmis-
sion combinations.
OPERATION
This cable causes the throttle control linkage to
open or close the throttle valve in response to move-
ment of the vacuum servo diaphragm.
REMOVAL
3.7L / 4.7L GAS
(1) Disconnect negative battery cable at battery.
(2) Remove air intake tube at top of throttle body.
The accelerator cable must be partially removed to
gain access to speed control cable.
(3) Hold throttle in wide open position. While held
in this position, slide throttle cable pin (Fig. 1) from
throttle body bellcrank.
(4) Using a pick or small screwdriver, press release
tab (Fig. 2) to release plastic cable mount from
bracket.Press on tab only enough to release
cable from bracket. If tab is pressed too much,
it will be broken.Slide plastic mount (Fig. 2)
towards right side of vehicle to remove throttle cable
from throttle body bracket.
(5) Using finger pressure only, disconnect servo
cable connector (Fig. 3) at throttle body bellcrank pin
by pushing connector off bellcrank pin towards front
of vehicle.DO NOT try to pull connector off per-
pendicular to the bellcrank pin. Connector will
be broken.
(6) Slide speed control cable plastic mount towards
right of vehicle to remove cable from throttle body
bracket (Fig. 4).
(7) Remove servo cable from servo. Refer to Servo
Removal/Installation.
5.9L Diesel Ð Auto. Trans.
(1) Disconnect both negative battery cables at both
batteries.
(2) Remove cable/lever/linkage cover. Refer to
Speed Control Servo Removal/Installation.
(3) Remove (disconnect) servo cable from servo.
Refer to Speed Control Servo Removal/Installation.(4) Using finger pressure only, disconnect end of
servo cable from throttle lever pin by pulling forward
on connector while holding lever rearward (Fig. 5).
DO NOT try to pull connector off perpendicular
to lever pin. Connector will be broken.
(5) Squeeze 2 pinch tabs (Fig. 5) on sides of speed
control cable at mounting bracket and push cable
rearward out of bracket.
Fig. 1 THROTTLE CABLE PIN - 3.7L / 4.7L
1 - THROTTLE CABLE PIN
2 - THROTTLE BODY BELLCRANK
3 - PUSH UP HERE
Fig. 2 THROTTLE CABLE RELEASE TAB - 3.7L /
4.7L
1 - THROTTLE CABLE
2 - RELEASE TAB
3 - PICK OR SCREWDRIVER
4 - PLASTIC CABLE MOUNT
8P - 4 SPEED CONTROLDR

(5) Before starting engine, operate accelerator
pedal to check for any binding.
(6) Install cable/lever cover.
SERVO
DESCRIPTION
A speed control servo is not used with any
5.7L V-8 engine, or with the 5.9L diesel engine
when equipped with a manual transmission.
The speed control servo is attached to the bottom
of the battery tray.
The servo unit consists of a solenoid valve body,
and a vacuum chamber. The solenoid valve body con-
tains three solenoids:
²Vacuum
²Vent
²Dump
The vacuum chamber contains a diaphragm with a
cable attached to control the throttle linkage.
OPERATION
A speed control servo is not used with any
5.7L V-8 engine, or with the 5.9L diesel engine
when equipped with a manual transmission.
The following information applies only to
vehicles equipped with a mechanical servo.
When/if a servo is used on gasoline powered vehi-
cles, the Powertrain Control Module (PCM) controls
the solenoid valve body. When/if a servo is used on
certain diesel powered vehicles, the Engine Control
Module (ECM) controls the solenoid valve body. The
solenoid valve body controls the application and
release of vacuum to the diaphragm of the vacuum
servo. The servo unit cannot be repaired and is ser-
viced only as a complete assembly.
Power is supplied to the servo's by the PCM/ECM
through the brake switch. The PCM/ECM controls
the ground path for the vacuum and vent solenoids.
The dump solenoid is energized anytime it receives
power. If power to the dump solenoid is interrupted,
the solenoid dumps vacuum in the servo. This pro-
vides a safety backup to the vent and vacuum sole-
noids.
The vacuum and vent solenoids must be grounded
at the PCM/ECM to operate. When the PCM/ECM
grounds the vacuum servo solenoid, the solenoid
allows vacuum to enter the servo and pull open the
throttle plate using the cable. When the PCM/ECM
breaks the ground, the solenoid closes and no more
vacuum is allowed to enter the servo. The PCM/ECM
also operates the vent solenoid via ground. The vent
solenoid opens and closes a passage to bleed or hold
vacuum in the servo as required.The PCM/ECM duty cycles the vacuum and vent
solenoids to maintain the set speed, or to accelerate
and decelerate the vehicle. To increase throttle open-
ing, the PCM/ECM grounds the vacuum and vent
solenoids. To decrease throttle opening, the PCM/
ECM removes the grounds from the vacuum and
vent solenoids. When the brake is released, if vehicle
speed exceeds 30 mph to resume, 35 mph to set, and
the RES/ACCEL switch has been depressed, ground
for the vent and vacuum circuits is restored.
REMOVAL
The speed control servo assembly is attached to the
bottom of the battery tray (Fig. 6).
(1) Disconnect negative battery cable at battery
(both cables at both batteries if diesel).
(2) To gain access to servo, remove plastic wheel-
house splash shield over left-front wheel.
(3) Disconnect vacuum line at servo (Fig. 6).
(4) Disconnect electrical connector at servo (Fig. 6).
(5) Remove 3 servo mounting screws (Fig. 6).
Depending on engine application, different sets of
mounting lugs (Fig. 6) are used to support servo to
battery tray. While removing, note proper lugs.
(6) Disconnect servo cable at throttle body. Refer to
Servo Cable Removal/Installation.
(7) Remove 2 mounting nuts holding servo cable
sleeve to bracket (Fig. 7).
(8) Pull speed control cable sleeve and servo away
from servo mounting bracket to expose cable retain-
ing clip (Fig. 7) and remove clip. Note: The servo
mounting bracket displayed in (Fig. 7) is a typical
bracket and may/may not be applicable to this model
vehicle.
(9) Remove servo from mounting bracket. While
removing, note orientation of servo to bracket.
INSTALLATION
(1) Position servo to mounting bracket (Fig. 7).
(2) Align hole in cable connector with hole in servo
pin. Install cable-to-servo retaining clip (Fig. 7).
(3) Insert servo mounting studs through holes in
servo mounting bracket.
(4) Install 2 servo-to-mounting bracket nuts and
tighten. Refer to torque specifications.
(5) Position servo assembly to correct mounting
lugs on battery tray (Fig. 6) and install 3 screws.
Tighten 3 screws. Refer to torque specifications.
(6) Connect vacuum line at servo.
(7) Connect electrical connector at servo.
(8) Connect servo cable to throttle body. Refer to
servo Cable Removal/Installation.
(9) Install left-front wheel-well liner.
(10) Connect negative battery cable to battery
(connect both cables if diesel).
8P - 6 SPEED CONTROLDR
CABLE (Continued)

WIPERS/WASHERS
TABLE OF CONTENTS
page page
WIPERS/WASHERS
DESCRIPTION..........................1
OPERATION............................4
DIAGNOSIS AND TESTING - WIPER &
WASHER SYSTEM.....................6
CLEANING - WIPER & WASHER SYSTEM.....6
INSPECTION - WIPER & WASHER SYSTEM . . . 7
CHECK VALVE
DESCRIPTION..........................7
OPERATION............................8
REMOVAL.............................8
INSTALLATION..........................8
WASHER FLUID LEVEL SWITCH
DESCRIPTION..........................9
OPERATION............................9
REMOVAL.............................10
INSTALLATION.........................11
WASHER HOSES/TUBES
DESCRIPTION.........................11
OPERATION...........................11
WASHER NOZZLE
DESCRIPTION.........................11
OPERATION...........................12
REMOVAL.............................12
INSTALLATION.........................12
WASHER PUMP/MOTOR
DESCRIPTION.........................13
OPERATION...........................13
REMOVAL.............................14
INSTALLATION.........................14
WASHER RESERVOIR
DESCRIPTION.........................14
OPERATION...........................15
REMOVAL
REMOVAL - EXCEPT DIESEL ENGINE.....15REMOVAL - DIESEL ENGINE............16
INSTALLATION
INSTALLATION - EXCEPT DIESEL ENGINE . . 17
INSTALLATION - DIESEL ENGINE.........17
WIPER ARM
DESCRIPTION.........................17
OPERATION...........................18
REMOVAL.............................18
INSTALLATION.........................18
WIPER BLADE
DESCRIPTION.........................18
OPERATION...........................19
REMOVAL.............................19
INSTALLATION.........................20
WIPER HIGH/LOW RELAY
DESCRIPTION.........................20
OPERATION...........................20
DIAGNOSIS AND TESTING - WIPER HIGH/
LOW RELAY.........................21
REMOVAL.............................21
INSTALLATION.........................22
WIPER MODULE
DESCRIPTION.........................22
OPERATION...........................23
REMOVAL.............................23
INSTALLATION.........................23
WIPER ON/OFF RELAY
DESCRIPTION.........................24
OPERATION...........................25
DIAGNOSIS AND TESTING - WIPER ON/OFF
RELAY..............................25
REMOVAL.............................26
INSTALLATION.........................26
WIPERS/WASHERS
DESCRIPTION
An electrically operated intermittent wiper and
washer system is standard factory-installed safety
equipment on this model (Fig. 1). The wiper and
washer system includes the following major compo-
nents, which are described in further detail else-
where in this service information:
²Check Valve- The washer system check valve
is integral to the wye fitting located in the washer
plumbing between the cowl plenum washer hose andthe washer nozzles, and is concealed beneath the
cowl plenum cover/grille panel at the base of the
windshield.
²Front Control Module- The Front Control
Module (FCM) is integral to the Integrated Power
Module (IPM). The IPM is located in the engine com-
partment, near the battery. (Refer to 8 - ELECTRI-
CAL/POWER DISTRIBUTION/INTEGRATED
POWER MODULE - DESCRIPTION).
²Instrument Cluster- In this model, the instru-
ment cluster is also sometimes referred to as the Cab
Control Node (CCN). The instrument cluster is
located in the instrument panel above the steering
DRWIPERS/WASHERS 8R - 1

washer system plumbing (Fig. 3). The check valve is
integral to the washer nozzle plumbing wye fitting
located in the cowl plenum area beneath the cowl
plenum cover/grille panel near the base of the wind-
shield. The check valve consists of a molded plastic
body with a raised arrowhead molded into its center
section that indicates the direction of the flow
through the valve, and three barbed hose nipples
formed in a wye configuration on the outside circum-
ference of the center section of the valve body. The
check valve cannot be adjusted or repaired and, if
faulty or damaged, it must be replaced.
OPERATION
The check valve provides more than one function
in this application. It serves as a wye connector fit-
ting between the engine compartment and washer
nozzle sections of the washer supply hose. It prevents
washer fluid from draining out of the washer supply
hoses back to the washer reservoir. This drain-back
would result in a lengthy delay from when the
washer switch is actuated until washer fluid was dis-
pensed through the washer nozzles, because the
washer pump would have to refill the washer plumb-
ing from the reservoir to the nozzles. Such a drain-
back condition could also result in water, dirt, or
other outside contaminants being siphoned into the
washer system through the washer nozzle orifice.
This water could subsequently freeze and plug the
nozzle, while other contaminants could interfere with
proper nozzle operation and cause improper nozzle
spray patterns. In addition, the check valve prevents
washer fluid from siphoning through the washer noz-
zles after the washer system is turned Off.When the washer pump pressurizes and pumps
washer fluid from the reservoir through the washer
plumbing, the fluid pressure unseats a diaphragm
from over a sump well within the valve by overriding
the spring pressure applied to it by a piston (Fig. 4).
With the diaphragm unseated, washer fluid is
allowed to flow toward the two washer nozzles. When
the washer pump stops operating, the spring pres-
sure on the piston seats the diaphragm over the
sump well in the valve and fluid flow in either direc-
tion within the washer plumbing is prevented. The
check valve cannot be adjusted or repaired and, if
faulty or damaged, it must be replaced.REMOVAL
(1) Remove both wiper arms from the wiper pivots.
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER ARM - REMOVAL).
(2) Unlatch and open the hood.
(3) Remove the cowl plenum cover/grille panel
from over the cowl plenum. (Refer to 23 - BODY/EX-
TERIOR/COWL GRILLE - REMOVAL).
(4) From the underside of the cowl plenum cover/
grille panel, disconnect the cowl plenum and washer
nozzle hoses from the three barbed nipples of the
check valve (Fig. 5).
(5) Remove the check valve from the underside of
the cowl plenum cover/grille panel.
INSTALLATION
(1) Position the check valve to the underside of the
cowl plenum cover/grille panel (Fig. 5). Be certain
that the flow direction arrow molded into the check
valve body is oriented towards the washer nozzles.
Fig. 3 Check Valve
1 - INLET NIPPLE
2 - CHECK VALVE
3 - OUTLET NIPPLE (2)
4 - FLOW DIRECTION ARROW
Fig. 4 Check Valve
1 - SPRING
2 - PISTON
3 - DIAPHRAGM
4 - TO WASHER NOZZLE
5 - FROM WASHER PUMP
8R - 8 WIPERS/WASHERSDR
CHECK VALVE (Continued)

(2) From the underside of the cowl plenum cover/
grille panel, reconnect the cowl plenum and washer
nozzle hoses to the three barbed nipples of the check
valve.
(3) Reinstall the cowl plenum cover/grille panel
over the cowl plenum. (Refer to 23 - BODY/EXTERI-
OR/COWL GRILLE - INSTALLATION).
(4) Close and latch the hood.
(5) Reinstall both wiper arms onto the wiper piv-
ots. (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER ARM - INSTALLATION).
WASHER FLUID LEVEL
SWITCH
DESCRIPTION
The washer fluid level switch is a single pole, sin-
gle throw reed-type switch mounted on the outboard
side of the of the washer reservoir in the engine com-
partment (Fig. 6). Only the molded plastic switch
mounting flange and the integral connector recepta-
cle are visible when the switch is installed in the res-
ervoir. A short nipple formation extends from the
inner surface of the switch mounting flange, and a
barb on the nipple near the switch mounting flange
is pressed through a rubber grommet seal installed
in the mounting hole of the reservoir.
A small, molded plastic float has two pivot pins
near its center that are snapped into two receptacles
near the ends of two stanchions that extend toward
the float from the switch nipple formation. A small
magnet is secured within the end of the float nearestthe switch nipple formation, and a reed switch is con-
cealed within the nipple. A diagnostic resistor is con-
nected between the two switch terminals within the
switch mounting flange. The washer fluid level
switch cannot be adjusted or repaired. If faulty or
damaged, the switch must be replaced.
OPERATION
The washer fluid level switch uses a pivoting,
oblong float to monitor the level of the washer fluid
in the washer reservoir. The float contains a small
magnet. When the float pivots, the proximity of this
magnet to a stationary reed switch within the nipple
formation of the switch changes. When the fluid level
in the washer reservoir is at or above the float level,
the float moves to a vertical position, the influence of
the float magnetic field is removed from the reed
switch, and the normally open reed switch contacts
open. When the fluid level in the washer reservoir
falls below the level of the pivoting float, the float
moves to a horizontal position, the influence of the
float magnetic field is applied to the reed switch, and
the contacts of the normally open reed switch close.
The washer fluid level switch is connected to the
vehicle electrical system through a dedicated take
out and connector of the right (except diesel engines)
or left (diesel engines only) headlamp and dash wire
harness. The switch is connected in series between a
clean ground output of the Front Control Module
Fig. 5 Check Valve Remove/Install
1 - WASHER NOZZLE HOSE (RIGHT)
2 - CHECK VALVE
3 - ROUTING CLIP
4 - COWL PLENUM WASHER HOSE
5 - COWL PLENUM COVER/GRILLE PANEL (UNDERSIDE)
6 - WASHER NOZZLE HOSE (LEFT)
Fig. 6 Washer Fluid Level Switch
1 - MOUNTING FLANGE
2 - BARBED NIPPLE
3 - FLOAT
4 - RESERVOIR
5 - GROMMET SEAL
6 - PIVOT
7 - MAGNET
8 - CONNECTOR RECEPTACLE
DRWIPERS/WASHERS 8R - 9
CHECK VALVE (Continued)

INSTALLATION
(1) Install a new rubber grommet seal into the
washer fluid level switch mounting hole in the
washer reservoir. Always use a new rubber grommet
seal on the reservoir.
(2) Insert the float of the washer fluid level switch
through the rubber grommet seal and into the
washer reservoir. The connector receptacle of the
washer fluid level switch should be pointed upward.
(3) Using hand pressure, press firmly and evenly
on the washer fluid level switch mounting flange
until the barbed nipple is fully seated in the rubber
grommet seal in the washer reservoir mounting hole.
(4) Reconnect the right (except diesel engine) or
left (diesel engine only) headlamp and dash wire har-
ness connector for the washer fluid level switch to
the switch connector receptacle (Fig. 7) or (Fig. 8).
(5) Reconnect the removed washer hose to the
barbed outlet nipple of the washer pump/motor unit.
(6) Refill the washer reservoir with the washer
fluid drained from the reservoir during the removal
procedure.
(7) Reconnect the battery negative cable.
(8) Close and latch the hood.
WASHER HOSES/TUBES
DESCRIPTION
The washer plumbing consists of a small diameter
rubber reservoir washer hose that is routed from the
barbed outlet nipple of the electric washer pump/mo-tor unit on the washer reservoir through a trough
molded into the back of the reservoir above the
washer pump and to the engine compartment washer
hose (Fig. 9). On models equipped with an optional
diesel engine, the reservoir washer hose is routed
through routing clips on the top of the radiator fan
shroud from the washer reservoir on the left side of
the radiator to the engine compartment washer hose
on the right side of the radiator. The engine compart-
ment washer hose is contained within the right head-
lamp and dash wire harness, which is routed through
the engine compartment along the top of the right
front fender wheel house to the dash panel.
The engine compartment washer hose is connected
to the washer reservoir washer hose and to the cowl
plenum washer hose with molded plastic in-line fit-
tings that have a barbed nipple on each end. The
cowl plenum washer hose is routed from the engine
compartment into the cowl plenum area through a
trough formation located near the right end of the
cowl plenum cover/grille panel. The cowl plenum
washer hose is connected to the washer system check
valve/wye fitting on the underside of the cowl plenum
cover/grille panel. The cowl plenum washer hose and
the two washer nozzle hoses are routed through inte-
gral routing clips on the underside of the cowl ple-
num cover/grille panel. The cowl plenum washer hose
is connected to one nipple on the wye fitting and the
two washer nozzle hoses are connected to the other
two wye fitting nipples. The washer nozzle hoses are
then routed along the underside of the cowl plenum
cover/grille panel to the two washer nozzles.
Washer hose is available for service only as roll
stock, which must then be cut to length. The molded
plastic washer hose fittings cannot be repaired. If
these fittings are faulty or damaged, they must be
replaced.
OPERATION
Washer fluid in the washer reservoir is pressurized
and fed by the washer pump/motor through the
washer system plumbing and fittings to the two
washer nozzles. Whenever routing the washer hose
or a wire harness containing a washer hose, it must
be routed away from hot, sharp, or moving parts;
and, sharp bends that might pinch the hose must be
avoided.
WASHER NOZZLE
DESCRIPTION
The two washer nozzles have integral snap fea-
tures and an anti-rotation tab that secure them in
dedicated holes in the cowl plenum cover/grille panel
located near the base of the windshield (Fig. 10). The
Fig. 9 Engine Compartment Washer Hose
1 - RIGHT FENDER
2 - RIGHT HEADLAMP & DASH WIRE HARNESS
3 - ENGINE COMPARTMENT WASHER HOSE (TO COWL
PLENUM)
4 - COWL PLENUM WASHER HOSE
5 - ENGINE COMPARTMENT WASHER HOSE (TO WASHER
RESERVOIR)
DRWIPERS/WASHERS 8R - 11
WASHER FLUID LEVEL SWITCH (Continued)

ENGINE
TABLE OF CONTENTS
page page
ENGINE - 3.7L............................ 1
ENGINE - 4.7L........................... 88ENGINE - 5.7L.......................... 180
ENGINE 5.9L DIESEL..................... 230
ENGINE - 3.7L
TABLE OF CONTENTS
page page
ENGINE - 3.7L
DESCRIPTION..........................3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION............4
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE............4
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL..............6
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - LUBRICATION..............7
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE..............8
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE.......8
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS..........9
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS..........9
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION........10
REMOVAL.............................10
INSTALLATION.........................11
SPECIFICATIONS
SPECIFICATIONS - 3.7L ENGINE.........12
TORQUE............................16
SPECIAL TOOLS.......................17
AIR CLEANER ELEMENT
REMOVAL.............................21
INSTALLATION.........................21
CYLINDER HEAD - LEFT
DIAGNOSIS AND TESTING - CYLINDER HEAD
GASKET............................21
REMOVAL.............................22
INSTALLATION.........................24
CAMSHAFT(S)
DESCRIPTION.........................25
REMOVAL.............................25INSTALLATION.........................27
CYLINDER HEAD COVER(S)
DESCRIPTION.........................27
REMOVAL.............................28
INSTALLATION.........................28
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION.........................28
STANDARD PROCEDURE - REFACING......28
REMOVAL.............................29
INSTALLATION.........................30
ROCKER ARM
DESCRIPTION.........................31
REMOVAL.............................31
INSTALLATION.........................31
VALVE GUIDE SEALS
DESCRIPTION.........................32
VALVE SPRINGS
DESCRIPTION.........................32
REMOVAL.............................32
INSTALLATION.........................32
CYLINDER HEAD - RIGHT
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER.....................32
REMOVAL.............................33
INSTALLATION.........................34
CAMSHAFT(S)
DESCRIPTION.........................35
REMOVAL.............................35
INSTALLATION.........................36
CYLINDER HEAD COVER(S)
REMOVAL.............................37
INSTALLATION.........................37
ROCKER ARM
DESCRIPTION.........................37
REMOVAL.............................37
VALVE GUIDE SEALS
DESCRIPTION.........................38
VALVE SPRINGS
DESCRIPTION.........................38
DRENGINE 9 - 1