Ignition coil removal DODGE RAM 1500 1998 2.G Owner's Manual

CONDITION POSSIBLE CAUSE CORRECTION
ENGINE STALLS OR ROUGH IDLE 1. Idle speed set to low. 1. (Refer to 14 - FUEL SYSTEM/
FUEL INJECTION/IDLE AIR
CONTROL MOTOR - REMOVAL).
2. Idle mixture too lean or too rich. 2. Refer to Powertrain Diagnosis
Information.
3. Vacuum leak. 3. Inspect intake manifold and
vacuum hoses, repair or replace as
necessary.
4. Faulty coil. 4. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION COIL
- REMOVAL).
5. Incorrect engine timing. 5. (Refer to 9 - ENGINE/VALVE
TIMING - STANDARD PROCEDURE).
1. ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped spark
plugs.1. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG -
CLEANING).
2. Dirt or water in fuel system. 2. Clean system and replace fuel
filter.
3. Faulty fuel pump. 3. (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/FUEL PUMP -
DIAGNOSIS AND TESTING).
4. Blown cylinder head gasket. 4. Replace cylinder head gasket.
5. Low compression. 5. (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING).
6. Burned, warped or pitted valves. 6. Replace as necessary.
7. Plugged or restricted exhaust
system.7. Inspect and replace as necessary.
8. Faulty coil. 8. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION COIL
- REMOVAL).
1. ENGINE MISSES ON
ACCELERATION1. Spark plugs dirty or incorrectly
gapped.1. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG -
CLEANING).
2. Dirt in fuel system. 2. Clean fuel system.
3. Burned, warped or pitted valves. 3. Replcae as necessary.
4. Faulty coil. 4. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION COIL
- REMOVAL).
1. ENGINE MISSES AT HIGH SPEED 1. Spark plugs dirty or incorrectly
gapped.1. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG -
CLEANING).
2. Faulty coil. 2. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION COIL
- REMOVAL).
3. Dirt or water in fuel system. 3. Clean system and replace fuel
filter.
9 - 184 ENGINE - 5.7LDR
ENGINE - 5.7L (Continued)

CAUTION: The head gaskets are marked ªTOPº to
indicate which side goes up.
(4) Position cylinder heads onto head gaskets and
cylinder block.
(5) Tighten the cylinder head bolts in three steps
(Fig. 4):
²Step 1Ð Snug tighten M12 cylinder head bolts,
in sequence, to 34 N´m (25 ft. lbs.) and M8 bolts to
20 N´m (15 ft. lbs.) torque.
²Step 2Ð Tighten M12 cylinder head bolts, in
sequence, to 54 N´m (40 ft. lbs.) and verify M8 bolts
to 20 N´m (15 ft. lbs.) torque..
²Step 3Ð Turn M12 cylinder head bolts, in
sequence, 90 degrees and tighten M8 bolts to 34 N´m
(25 ft. lbs.) torque.
(6) Install push rods and rocker arm assemblies in
their original position.
(7) Install the intake manifold and throttle body
assembly.
(8) If required, adjust spark plugs to specifications.
Install the plugs.
(9) Connect the heater hoses.
(10) Install the fuel supply line.
(11) Install the generator and drive belt.
(12) Install cylinder head covers(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(13) Connect the evaporation control system.
(14) Install the air cleaner.
(15) Fill cooling system.
(16) Connect the negative cable to the battery.
(17) Start engine check for leaks.CYLINDER HEAD COVER(S)
REMOVAL
(1) Disconnect battery negative cable.
(2) Disconnect coil on plug connectors.
CAUTION: The ground straps must be installed in
the same location as removed. The covers are
machined to accept the ground straps in those
locations only.
(3) Remove cylinder head cover retaining bolts,
and ground straps.
(4) Remove cylinder head cover.
NOTE: The gasket may be used again, provided no
cuts, tears, or deformation has occurred.
INSTALLATION
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
CAUTION: DO NOT allow other components includ-
ing the wire harness to rest on or against the
engine cylinder head cover. Prolonged contact with
other objects may wear a hole in the cylinder head
cover.
(1) Clean cylinder head cover and both sealing sur-
faces. Inspect and replace gasket as necessary.
(2)
Install cylinder head cover and hand start all fas-
teners. Verify that all double ended studs are in the cor-
rect location and install left and right ground straps.
CAUTION: The ground straps must be installed in
the same location as removed. The covers are
machined to accept the ground straps in those
locations only.
NOTE: The right hand ground strap is located on
the front inboard stud. The left hand ground strap
is located on the rear inboard stud.
(3) Tighten cylinder head cover bolts and double
ended studs to 8 N´m (70 in. lbs). Begin torque
sequence in the middle of head cover and torque
bolts moving outward in a crisscross pattern from top
to bottom.
(4) Install ignition coil on plug, and torque fasten-
ers to 12 N´m (105 in. lbs)
(5) Connect, ignition coil electrical connectors.
(6) Install PCV hose.
(7) Connect battery negative cable.
Fig. 4 CYLINDER HEAD TIGHTENING SEQUENCE
DRENGINE - 5.7L 9 - 201
CYLINDER HEAD (Continued)

VALVE SPRINGS
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove air cleaner assembly.
(3) Remove air intake resonator.
(4) Remove spark plug cables.
(5) Remove ignition coil connectors (Fig. 6).
(6) Remove ignition coils.
(7) Remove one spark plug.
(8) Remove valve cover.
CAUTION: The piston must be at TDC, and both
valves closed on the cylinder to be serviced.
NOTE: If removing intake valve spring, install spe-
cial tool# 9070, pushrod retaining plate, to retain
the intake pushrods.
(9) Remove exhaust/intake rocker arm shafts.
(10) Install spring compressor, special tool# 9065.
NOTE: All valve springs and seals are removed in
the same manner.(11) Charge cylinder with air.
NOTE: Tap the top of the valve spring retainer to
loosen the spring retainers locks.
(12) Compress valve spring and remove valve
retainer locks.
(13) Release spring compressor and remove valve
spring.
NOTE: The valve springs are interchangeable
between intake and exhaust.
(14) Remove valve seal.
INSTALLATION
(1) Install valve seal.
(2) Install valve spring.
(3) Using special tool# 9065, compress valve spring
and install valve spring retainer and locks.
(4) Release air charge in cylinder.
(5) Remove spring compressor tool # 9065.
CAUTION: Verify that the pushrods are fully seated
into lifter and rocker arm. Recheck after rocker arm
shaft has been torqued to specification.
(6) Install rocker arm shaft and pushrods(Refer to
9 - ENGINE/CYLINDER HEAD/ROCKER ARM /
ADJUSTER ASSY - INSTALLATION).
(7) Tighten the rocker shaft bolts to 22 N´m (195
in. lbs.) torque,using the following sequence:Center,
center-right, center-left, right, left.
(8) Remove special tool# 9070, pushrod retaining
plate, if used.
(9) Install cylinder head cover.
(10) Tighten cylinder head cover bolts and double
ended studs(Refer to 9 - ENGINE/CYLINDER
HEAD/CYLINDER HEAD COVER(S) - INSTALLA-
TION).
(11) Install spark plugs.
(12) Install ignition coil on plug, and torque fas-
teners to 12 N´m (105 in. lbs)
(13) Install ignition coil connectors.
(14) Install spark plug cables.
(15) Install air intake resonator.
(16) Install air cleaner assembly.
(17) Connect negative battery cable.
Fig. 6 IGNITION COIL R/I Ð 5.7L V-8
1 - SLIDE LOCK (SLIDE OUTWARD TO UNLOCK)
2 - SPARK PLUG CABLE (TO OPPOSITE CYLINDER BANK
SPARK PLUG)
3 - RELEASE LOCK / TAB (PUSH HERE)
4 - ELEC. CONNECTOR
5 - IGNITION COIL
6 - COIL MOUNTING BOLTS (2)
7 - SPARK PLUG CABLE (TO OPPOSITE CYLINDER BANK
IGNITION COIL)
9 - 204 ENGINE - 5.7LDR

REMOVAL
3.7L V-6
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT PRESSURE EVEN WITH ENGINE OFF.
BEFORE SERVICING FUEL RAIL, FUEL SYSTEM
PRESSURE MUST BE RELEASED.
CAUTION: The left and right fuel rails are replaced
as an assembly. Do not attempt to separate rail
halves at connector tubes (Fig. 18). Due to design
of tubes, it does not use any clamps. Never attempt
to install a clamping device of any kind to tubes.
When removing fuel rail assembly for any reason,
be careful not to bend or kink tubes.
(1) Remove fuel tank filler tube cap.
(2) Perform Fuel System Pressure Release Proce-
dure.
(3) Remove negative battery cable at battery.
(4) Remove air duct at throttle body air box.
(5) Remove air box at throttle body.
(6) Remove air resonator mounting bracket at
front of throttle body (2 bolts).
(7) Disconnect fuel line latch clip and fuel line at
fuel rail. A special tool will be necessary for fuel line
disconnection. Refer to Quick-Connect Fittings.
(8) Remove necessary vacuum lines at throttle
body.
(9) Disconnect electrical connectors at all 6 fuel
injectors. To remove connector refer to (Fig. 17). Push
red colored slider away from injector (1). While push-
ing slider, depress tab (2) and remove connector (3)
from injector. The factory fuel injection wiring har-
ness is numerically tagged (INJ 1, INJ 2, etc.) for
injector position identification. If harness is not
tagged, note wiring location before removal.
(10) Disconnect electrical connectors at all throttle
body sensors.
(11) Remove 6 ignition coils. Refer to Ignition Coil
Removal/Installation.
(12) Remove 4 fuel rail mounting bolts (Fig. 18).
(13) Gently rock and pullleftside of fuel rail until
fuel injectors just start to clear machined holes in
cylinder head. Gently rock and pullrightside of rail
until injectors just start to clear cylinder head holes.
Repeat this procedure (left/right) until all injectors
have cleared cylinder head holes.
(14) Remove fuel rail (with injectors attached)
from engine.
(15) If fuel injectors are to be removed, refer to
Fuel Injector Removal/Installation.
Fig. 17 REMOVE/INSTALL INJECTOR CONNECTOR
Fig. 18 FUEL RAIL REMOVE/INSTALL - 3.7L V-6
1 - MOUNTING BOLTS (4)
2 - QUICK-CONNECT FITTING
3 - FUEL RAIL
4 - INJ. #1
5 - INJ. #3
6 - INJ. #5
7 - INJ. #2
8 - INJ. #4
9 - INJ. #6
10 - CONNECTOR TUBE
DRFUEL DELIVERY - GAS 14 - 13
FUEL RAIL (Continued)

4.7L V-8
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT PRESSURE EVEN WITH ENGINE OFF.
BEFORE SERVICING FUEL RAIL, FUEL SYSTEM
PRESSURE MUST BE RELEASED.
CAUTION: The left and right fuel rails are replaced
as an assembly. Do not attempt to separate rail
halves at connector tubes (Fig. 19). Due to design
of tubes, it does not use any clamps. Never attempt
to install a clamping device of any kind to tubes.
When removing fuel rail assembly for any reason,
be careful not to bend or kink tubes.
(1) Remove fuel tank filler tube cap.
(2) Perform Fuel System Pressure Release Proce-
dure.
(3) Remove negative battery cable at battery.
(4) Remove air duct at throttle body air box.
(5) Remove air box at throttle body.
(6) Remove air resonator mounting bracket at
front of throttle body (2 bolts).
(7) Disconnect fuel line latch clip and fuel line at
fuel rail. A special tool will be necessary for fuel line
disconnection. Refer to Quick-Connect Fittings.
(8) Remove necessary vacuum lines at throttle
body.
(9) Disconnect electrical connectors at all 8 fuel
injectors. To remove connector refer to (Fig. 17). Push
red colored slider away from injector (1). While push-
ing slider, depress tab (2) and remove connector (3)
from injector. The factory fuel injection wiring har-
ness is numerically tagged (INJ 1, INJ 2, etc.) for
injector position identification. If harness is not
tagged, note wiring location before removal.
(10) Disconnect electrical connectors at all throttle
body sensors.
(11) Remove 8 ignition coils. Refer to Ignition Coil
Removal/Installation.
(12) Remove 4 fuel rail mounting bolts (Fig. 19).
(13) Gently rock and pullleftside of fuel rail until
fuel injectors just start to clear machined holes in
cylinder head. Gently rock and pullrightside of rail
until injectors just start to clear cylinder head holes.
Repeat this procedure (left/right) until all injectors
have cleared cylinder head holes.
(14) Remove fuel rail (with injectors attached)
from engine.
(15) If fuel injectors are to be removed, refer to
Fuel Injector Removal/Installation.
5.7L V-8
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT PRESSURE EVEN WITH ENGINE OFF.
BEFORE SERVICING FUEL RAIL, FUEL SYSTEM
PRESSURE MUST BE RELEASED.
CAUTION: The left and right fuel rails are replaced
as an assembly. Do not attempt to separate rail
halves at connector tube (Fig. 20). Due to design of
tube, it does not use any clamps. Never attempt to
install a clamping device of any kind to tube. When
removing fuel rail assembly for any reason, be care-
ful not to bend or kink tube.
(1) Remove fuel tank filler tube cap.
Fig. 19 FUEL RAIL REMOVE/INSTALL - 4.7L V-8
1 - MOUNTING BOLTS (4)
2 - INJ.#7
3 - INJ.#5
4 - QUICK-CONNECT FITTING
5 - INJ.#3
6 - FUEL INJECTOR RAIL
7 - INJ.#1
8 - CONNECTOR TUBE
9 - INJ.#2
10 - INJ.#4
11 - INJ.#6
12 - INJ.#8
13 - PRESSURE TEST PORT CAP
14 - 14 FUEL DELIVERY - GASDR
FUEL RAIL (Continued)

(2) Perform Fuel System Pressure Release Proce-
dure.
(3) Remove negative battery cable at battery.
(4) Remove flex tube (air cleaner housing to
engine).
(5) Remove air resonator box at throttle body.
(6) Disconnect all spark plug cables from all spark
plugs and ignition coils. Do not remove cables from
cable routing tray. Note original cable positions while
removing (Fig. 22).
(7) Remove spark plug cable tray from engine by
releasing 4 retaining clips (Fig. 21). Remove tray and
cables from engine as an assembly.
(8) Disconnect electrical connectors at all 8 igni-
tion coils. Refer to Ignition Coil Removal/Installation.
(9) Disconnect fuel line latch clip and fuel line at
fuel rail. A special tool will be necessary for fuel line
disconnection. Refer to Quick-Connect Fittings.
(10) Disconnect electrical connectors at all 8 fuel
injectors. To remove connector refer to (Fig. 17). Push
red colored slider away from injector (1). While push-
ing slider, depress tab (2) and remove connector (3)
from injector. The factory fuel injection wiring har-
ness is numerically tagged (INJ 1, INJ 2, etc.) for
injector position identification. If harness is not
tagged, note wiring location before removal.
(11) Disconnect electrical connectors at all throttle
body sensors.
(12) Remove 4 fuel rail mounting bolts and hold-
own clamps (Fig. 20).
(13) Gently rock and pullleftside of fuel rail until
fuel injectors just start to clear machined holes in
intake manifold. Gently rock and pullrightside of
rail until injectors just start to clear intake manifold
head holes. Repeat this procedure (left/right) until all
injectors have cleared machined holes.
(14) Remove fuel rail (with injectors attached)
from engine.
(15) If fuel injectors are to be removed, refer to
Fuel Injector Removal/Installation.
INSTALLATION
3.7L V-6
(1) If fuel injectors are to be installed, refer to Fuel
Injector Removal/Installation.
(2) Clean out fuel injector machined bores in
intake manifold.
(3) Apply a small amount of engine oil to each fuel
injector o-ring. This will help in fuel rail installation.
(4) Position fuel rail/fuel injector assembly to
machined injector openings in cylinder head.
(5) Guide each injector into cylinder head. Be care-
ful not to tear injector o-rings.
(6) Pushrightside of fuel rail down until fuel
injectors have bottomed on cylinder head shoulder.Pushleftfuel rail down until injectors have bot-
tomed on cylinder head shoulder.
Fig. 20 5.7L FUEL RAIL
1 - FUEL RAIL
2 - MOUNTING BOLT
3 - HOLDOWN CLAMPS
4 - CONNECTOR TUBE
Fig. 21 5.7L SPARK PLUG CABLE ROUTING TRAY
1 - SPARK PLUG CABLES
2 - RETAINING CLIP
3 - SPARK PLUG CABLE ROUTING TRAY
DRFUEL DELIVERY - GAS 14 - 15
FUEL RAIL (Continued)

(7) Install 4 fuel rail mounting bolts and tighten.
Refer to torque specifications.
(8) Install 6 ignition coils. Refer to Ignition Coil
Removal/Installation.
(9) Connect electrical connectors to throttle body.
(10) Connect electrical connectors at all fuel injec-
tors. To install connector, refer to (Fig. 17). Push con-
nector onto injector (1) and then push and lock red
colored slider (2). Verify connector is locked to injec-
tor by lightly tugging on connector.
(11) Connect necessary vacuum lines to throttle
body.
(12) Install air resonator mounting bracket near
front of throttle body (2 bolts).
(13) Connect fuel line latch clip and fuel line to
fuel rail. Refer to Quick-Connect Fittings.
(14) Install air box to throttle body.
(15) Install air duct to air box.
(16) Connect battery cable to battery.
(17) Start engine and check for leaks.
4.7L V-8
(1) If fuel injectors are to be installed, refer to Fuel
Injector Removal/Installation.
(2) Clean out fuel injector machined bores in
intake manifold.(3) Apply a small amount of engine oil to each fuel
injector o-ring. This will help in fuel rail installation.
(4) Position fuel rail/fuel injector assembly to
machined injector openings in cylinder head.
(5) Guide each injector into cylinder head. Be care-
ful not to tear injector o-rings.
(6) Pushrightside of fuel rail down until fuel
injectors have bottomed on cylinder head shoulder.
Pushleftfuel rail down until injectors have bot-
tomed on cylinder head shoulder.
(7) Install 4 fuel rail mounting bolts and tighten.
Refer to torque specifications.
(8) Install 8 ignition coils. Refer to Ignition Coil
Removal/Installation.
(9) Connect electrical connectors to throttle body.
(10) Connect electrical connectors at all fuel injec-
tors. To install connector, refer to (Fig. 17). Push con-
nector onto injector (1) and then push and lock red
colored slider (2). Verify connector is locked to injec-
tor by lightly tugging on connector.
(11) Connect necessary vacuum lines to throttle
body.
(12) Install air resonator mounting bracket near
front of throttle body (2 bolts).
(13) Connect fuel line latch clip and fuel line to
fuel rail. Refer to Quick-Connect Fittings.
(14) Install air box to throttle body.
Fig. 22 5.7L SPARK PLUG CABLE ROUTING
1 - #8 COIL-TO- #5 SPARK PLUG (MARKED 5/8) 7 - CABLE TRAY
2 - #5 COIL-TO- #8 SPARK PLUG (MARKED 5/8) 8 - CLIPS (SPARK PLUG CABLE-TO-TRAY- RETENTION)
3 - #7 COIL-TO- #4 SPARK PLUG (MARKED 4/7) 9 - #2 COIL-TO- #3 SPARK PLUG (MARKED 2/3)
4 - #3 COIL-TO- #2 SPARK PLUG (MARKED 2/3) 10 - #6 COIL-TO- #1 SPARK PLUG (MARKED 1/6)
5 - #1 COIL-TO- #6 SPARK PLUG (MARKED 1/6) 11 - #4 COIL-TO- #7 SPARK PLUG (MARKED 4/7)
6 - CLIPS (TRAY-TO-MANIFOLD RETENTION)
14 - 16 FUEL DELIVERY - GASDR
FUEL RAIL (Continued)

(15) Install air duct to air box.
(16) Connect battery cable to battery.
(17) Start engine and check for leaks.
5.7L V-8
(1) If fuel injectors are to be installed, refer to Fuel
Injector Removal/Installation.
(2) Clean out fuel injector machined bores in
intake manifold.
(3) Apply a small amount of engine oil to each fuel
injector o-ring. This will help in fuel rail installation.
(4) Position fuel rail/fuel injector assembly to
machined injector openings in intake manifold.
(5) Guide each injector into intake manifold. Be
careful not to tear injector o-rings.
(6) Pushrightside of fuel rail down until fuel
injectors have bottomed on shoulders. Pushleftfuel
rail down until injectors have bottomed on shoulders.
(7) Install 4 fuel rail holdown clamps and 4 mount-
ing bolts. Refer to Torque Specifications.
(8) Position spark plug cable tray and cable assem-
bly to intake manifold. Snap 4 cable tray retaining
clips into intake manifold.
(9) Install all cables to spark plugs and ignition
coils.
(10) Connect electrical connector to throttle body.
(11) Install electrical connectors to all 8 ignition
coils. Refer to Ignition Coil Removal/Installation.
(12) Connect electrical connector to throttle body.
(13) Connect electrical connectors at all fuel injec-
tors. To install connector, refer to (Fig. 17). Push con-
nector onto injector (1) and then push and lock red
colored slider (2). Verify connector is locked to injec-
tor by lightly tugging on connector.
(14) Connect fuel line latch clip and fuel line to
fuel rail. Refer to Quick-Connect Fittings.
(15) Install air resonator to throttle body (2 bolts).
(16) Install flexible air duct to air box.
(17) Connect battery cable to battery.
(18) Start engine and check for leaks.
FUEL TANK
DESCRIPTION
The fuel tank is constructed of a plastic material.
Its main functions are for fuel storage and for place-
ment of the fuel pump module, and (if equipped) cer-
tain ORVR components.
OPERATION
All models pass a full 360 degree rollover test
without fuel leakage. To accomplish this, fuel and
vapor flow controls are required for all fuel tank con-
nections.Two check (control) valves are mounted into the
top of the fuel tank. Refer to Fuel Tank Check Valve
for additional information.
An evaporation control system is connected to the
fuel tank to reduce emissions of fuel vapors into the
atmosphere. When fuel evaporates from the fuel
tank, vapors pass through vent hoses or tubes to a
charcoal canister where they are temporarily held.
When the engine is running, the vapors are drawn
into the intake manifold. Certain models are also
equipped with a self-diagnosing system using a Leak
Detection Pump (LDP) and/or an On-Board Refueling
Vapor Recovery (ORVR) system. Refer to Emission
Control System for additional information.
REMOVAL- EXCEPT DIESEL
Fuel Tank Draining
WARNING: THE FUEL SYSTEM MAY BE UNDER
CONSTANT FUEL PRESSURE EVEN WITH THE
ENGINE OFF. THIS PRESSURE MUST BE
RELEASED BEFORE SERVICING FUEL TANK.
Two different procedures may be used to drain fuel
tank: through the fuel fill fitting on tank, or using
the DRBtscan tool. Due to a one-way check valve
installed into the fuel fill opening fitting at the tank,
the tank cannot be drained conventionally at the fill
cap.
The quickest draining procedure involves removing
the rubber fuel fill hose.
As an alternative procedure, the electric fuel pump
may be activated allowing tank to be drained at fuel
rail connection. Refer to DRB scan tool for fuel pump
activation procedures. Before disconnecting fuel line
at fuel rail, release fuel pressure. Refer to the Fuel
System Pressure Release Procedure for procedures.
Attach end of special test hose tool number 6541,
6539, 6631 or 6923 at fuel rail disconnection (tool
number will depend on model and/or engine applica-
tion). Position opposite end of this hose tool to an
approved gasoline draining station. Activate fuel
pump and drain tank until empty.
If electric fuel pump is not operating, fuel must be
drained through fuel fill fitting at tank. Refer to fol-
lowing procedures.
(1) Release fuel system pressure.
(2) Raise vehicle.
(3) Thoroughly clean area around fuel fill fitting
and rubber fuel fill hose at tank.
(4) If vehicle is equipped with 4 doors and a 6 foot
(short) box, remove left-rear tire/wheel.
(5) Loosen clamp (Fig. 23) and disconnect rubber
fuel fill hose at tank fitting. Using an approved gas
holding tank, drain fuel tank through this fitting.
DRFUEL DELIVERY - GAS 14 - 17
FUEL RAIL (Continued)

GEAR - LINK/COIL
TABLE OF CONTENTS
page page
GEAR - LINK/COIL
DESCRIPTION.........................20
OPERATION...........................20
REMOVAL.............................20
INSTALLATION.........................21
ADJUSTMENTS
ADJUSTMENT........................21
SPECIFICATIONS
POWER STEERING GEAR..............22
TORQUE CHART......................23
SPECIAL TOOLS
POWER STEERING GEAR..............23
PITMAN SHAFT SEAL
REMOVAL
REMOVAL - GAS ENGINE...............25REMOVAL - DIESEL...................25
INSTALLATION
INSTALLATION - GAS ENGINE...........26
INSTALLATION - DIESEL................26
STEERING GEAR INPUT SHAFT SEAL
REMOVAL.............................27
INSTALLATION.........................29
PITMAN SHAFT
REMOVAL
REMOVAL - GAS......................30
REMOVAL - DIESEL...................30
INSTALLATION
INSTALLATION - GAS..................31
INSTALLATION - DIESEL................31
GEAR - LINK/COIL
DESCRIPTION
The power steering gear is a recirculating ball type
gear (Fig. 1). The gear ratio's used are 12.5:1.
OPERATION
The gear acts as a rolling thread between the
worm shaft and rack piston. The worm shaft is sup-
ported by a thrust bearing at the lower end and a
bearing assembly at the upper end. When the worm
shaft is turned from input from the steering column
the rack piston moves. The rack piston teeth mesh
with the pitman shaft. Turning the worm shaft, turns
the pitman shaft, which turns the steering linkage.
REMOVAL
(1) Place the front wheels in a straight-ahead posi-
tion.
NOTE: The steering column on vehicles with an
automatic transmission may not be equipped with
an internal locking shaft that allows the ignition key
cylinder to be locked with the key. Alternative meth-
ods of locking the steering wheel for service will
have to be used.
(2) Lock the steering wheel.
(3) Siphon out as much power steering fluid as
possible.
Fig. 1 STEERING GEAR
1 - INPUT SHAFT
2 - OUTLET
3 - INLET
4 - VALVE ASSEMBLY HOUSING
5 - PITMAN SHAFT COVER BOLTS
6 - STEERING GEAR
7 - MESHLOAD ADJUSTER NUT
8 - PITMAN SHAFT
19 - 20 GEAR - LINK/COILDR

spikes and electromagnetic interference that can be
generated as the electromagnetic field of the relay
coil collapses.
The A/C compressor clutch relay terminals are con-
nected to the vehicle electrical system through a
receptacle in the integrated power module (IPM). The
inputs and outputs of the A/C compressor clutch
relay include:
²The common feed terminal (30) receives a bat-
tery current input from a fuse in the IPM through a
fused B(+) circuit at all times.
²The coil ground terminal (86) receives a ground
input from the PCM/ECM through the A/C compres-
sor clutch relay control circuit only when the PCM/
ECM electronically pulls the control circuit to
ground.
²The coil battery terminal (85) receives a battery
current input from PTC 1 in the IPM through a
fused ignition switch output (run) circuit only when
the ignition switch is in the On position.
²The normally open terminal (87) provides a bat-
tery current output to the compressor clutch coil
through the A/C compressor clutch relay output cir-
cuit only when the A/C compressor clutch relay coil is
energized.
²The normally closed terminal (87A) is not con-
nected to any circuit in this application, but provides
a battery current output only when the A/C compres-
sor clutch relay coil is de-energized.
Refer to the appropriate wiring information for
diagnosis and testing of the micro-relay and for com-
plete HVAC wiring diagrams.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the cover from the integrated power
module (IPM) (Fig. 11).
(3) Refer to the fuse and relay layout label on the
IPM cover for compressor clutch relay identification
and location.
(4) Remove the A/C compressor clutch relay from
the IPM.
INSTALLATION
(1) See the fuse and relay layout label affixed to
the underside of the IPM cover for A/C compressor
clutch relay location.
(2) Position the A/C compressor clutch relay in the
proper receptacle in the IPM.
(3) Align the A/C compressor clutch relay termi-
nals with the terminal cavities in the IPM receptacle.
(4) Push down firmly on the A/C compressor clutch
relay until the terminals are fully seated in the ter-
minal cavities in the IPM receptacle.
(5) Install the cover onto the IPM.(6) Reconnect the negative battery cable.
A/C HEATER CONTROL
DESCRIPTION
The heater and air conditioning systems use elec-
trical controls. These controls provide the vehicle
operator with a number of setting options to help
control the climate and comfort within the vehicle.
The A/C-heater control for the Single Zone system
(Fig. 12) or Dual Zone system (Fig. 13) is located to
the right of the instrument cluster on the instrument
panel.
The Single Zone control panel contains a rotary-
type temperature control switch, a rotary-type mode
control switch and a rotary-type blower motor speed
switch. The A/C-heater control also has a push but-
ton to activate the optional heated side view mirror
defroster elements and to turn the A/C on.
The Dual Zone control panel contains a pair of slid-
er-type temperature control switches, a rotary-type
mode control switch and a rotary-type blower motor
speed switch. The control also has buttons to activate
the optional heated sideview mirror defroster ele-
ments, turn the A/C on and set the system to Max
A/C.
The A/C-heater control panel cannot be repaired. If
faulty or damaged, the entire unit must be replaced.
Fig. 11 Integrated Power Module (IPM)
1 - BATTERY
2 - INTEGRATED POWER MODULE (IPM)
24 - 14 CONTROLSDR
A/C COMPRESSOR CLUTCH RELAY (Continued)