Auxiliary outlet DODGE RAM 1500 1998 2.G Workshop Manual

REMOVAL
(1) Disconnect the battery negative cable.
(2) Place a drain pan under the oil cooler lines.
(3) Disconnect the transmission oil cooler line
quick-connect fitting at the cooler outlet using the
quick connect release tool 6935. Plug the cooler lines
to prevent oil leakage.
(4) Unsnap the transmission cooler tubes from the
radiator tank clips.
(5) Remove the bolt attaching the transmission
cooler to the radiator.
(6) Remove oil cooler from the vehicle. Take care
not to damage the radiator core or transmission
cooler tubes.
INSTALLATION
(1) Position the transmission cooler tubes to the
front of the radiator by sliding brackets into slots on
radiator inlet tank.
(2) Snap the transmission cooler tubes into the
clips on the side of the radiator tank.
(3) Install the transmission cooler attaching bolt.
Tighten the bolt to 16 N´m (140 in. lbs.).
(4) Inspect the quick connect fittings for debris
and install the quick connect fitting on the cooler
tube until an audible ªclickº is heard. Pull apart the
connection to verify proper installation and install
the secondary latches.
(5) Connect the battery negative cable.
(6) Start the engine and check all fittings for
leaks.
(7) Check the fluid level in the automatic trans-
mission. Refer to the appropriate transmission sec-
tion(Refer to 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC - 45RFE/545RFE/FLUID - STANDARD
PROCEDURE) or(Refer to 21 - TRANSMISSION/
TRANSAXLE/AUTOMATIC - 46RE/FLUID - STAN-
DARD PROCEDURE).
TRANS COOLER - 5.9L DIESEL
DESCRIPTION
All diesel models equipped with an automatic
transmission are equipped with both a main water-
to-oil cooler and a separate air-to-oil cooler. Both cool-
ers are supplied as standard equipment on diesel
engine powered models when equipped with an auto-
matic transmission.
The main water-to-oil transmission oil cooler is
mounted to a bracket on the intake side of the engine
(Fig. 3).
The air-to-oil cooler is located in front of the radi-
ator (Fig. 4).
Fig. 3 Transmission Water-To-Oil Cooler - Diesel
Engine - Typical
1 - TRANSMISSION WATER-TO-OIL COOLER
Fig. 4 Auxiliary Transmission Oil CoolerÐDiesel
Engine
1 - MOUNTING BOLTS
2 - THERMOSTATIC BYPASS VALVE
3 - RADIATOR
4 - QUICK-CONNECT FITTINGS
5 - TRANSMISSION OIL COOLER
7 - 68 TRANSMISSIONDR
TRANS COOLER (Continued)

8W-02 COMPONENT INDEX
Component Page
A/C Compressor Clutch................. 8W-42
A/C Compressor Clutch Relay............ 8W-42
A/C Pressure Transducer................ 8W-42
A/C-Heater Control.................... 8W-42
Accelerator Pedal Position Sensor......... 8W-30
Adjustable Pedal Motor................. 8W-30
Adjustable Pedal Relay................. 8W-30
Adjustable Pedal Switch................ 8W-30
Airbag Control Module................. 8W-43
Airbag-Squibs........................ 8W-43
Airbag-Curtains....................... 8W-43
Airbag-Passenger On/Off Switch.......... 8W-43
Ambient Temperature Sensor............ 8W-49
Amplifier Audio....................... 8W-47
Ashtray Lamp........................ 8W-44
Auto Shut Down Relay................. 8W-30
Automatic Day/Night Mirror.......... 8W-49, 55
Auxiliary Battery..................... 8W-20
Backup Lamp Switch.................. 8W-51
Battery............................. 8W-20
Battery Temperature Sensor............. 8W-30
Blend Door Actuators.................. 8W-42
Blower Motor......................... 8W-42
Blower Motor Resistor Block............. 8W-42
Brake Fluid Level Switch............ 8W-34, 35
Brake Lamp Switch.................... 8W-33
Brake Transmission Shift Interlock
Solenoid........................... 8W-40
Camshaft Position Sensor............... 8W-30
Capacitor............................ 8W-30
Center High Mounted Stop Lamp-
Aftermarket........................ 8W-51
Center High Mounted Stop Lamp/Cargo
Lamp.......................... 8W-44, 51
Cigar Lighter Outlet................... 8W-41
Circuit Breaker....................... 8W-10
Clearance Lamps...................... 8W-50
Clockspring................. 8W-33, 41, 43, 47
Clutch Interlock Brake Switch........... 8W-21
Coil On Plugs........................ 8W-30
Compass/Mini-Trip Computer............ 8W-49
Condenser Fan....................... 8W-42
Condenser Fan Relay.................. 8W-42
Controller Antilock Brake............ 8W-34, 35
Crankshaft Position Sensor.............. 8W-30
Cylinder Lock Switch-Driver............. 8W-61
Data Link Connector................... 8W-18
Data Link Connector-Engine............. 8W-18
Dome Lamp....................... 8W-44, 49
Door Ajar Switches.................... 8W-40
Door Lock Motor/Ajar Switches........ 8W-40, 61
Door Lock Switch-Passenger............. 8W-61Component Page
Door Module................... 8W-60, 61, 62
EGR Solenoid........................ 8W-30
Electric Backlight..................... 8W-48
Electric Brake Provision................ 8W-54
Electronic Throttle Control Module........ 8W-30
Engine Control Module................. 8W-30
Engine Coolant Temperature Sensor....... 8W-30
Engine Oil Pressure Switch.............. 8W-30
EVAP/Purge Solenoid.................. 8W-30
Evaporator Temperature Sensor.......... 8W-42
Fender Lamps........................ 8W-51
Fog Lamp Relay...................... 8W-50
Fog Lamps.......................... 8W-50
Front Control Module.................. 8W-10
Fuel Control Actuator.................. 8W-30
Fuel Heater.......................... 8W-30
Fuel Heater Relay..................... 8W-30
Fuel Injector Packs.................... 8W-30
Fuel Injectors........................ 8W-30
Fuel Pump Module.................... 8W-30
Fuel Pump Motor..................... 8W-30
Fuel Pump Relay...................... 8W-30
Fuses............................ 8W-10, 33
Fusible Link......................... 8W-10
Generator........................... 8W-20
Glove Box Lamp And Switch............. 8W-44
Grounds............................ 8W-15
Hands Free Module.................... 8W-55
Headlamp Switch.................. 8W-40, 50
Headlamps.......................... 8W-50
Heated Mirror Relay................... 8W-62
Heated Seat Cushions.................. 8W-63
Horn Relay.......................... 8W-41
Horn Switch......................... 8W-41
Horn-High Note....................... 8W-41
Horn-Low Note....................... 8W-41
Idle Air Control Motor.................. 8W-30
Ignition Switch....................... 8W-10
Inlet Air Temperature Sensor............ 8W-30
Input Speed Sensor.................... 8W-31
Instrument Cluster.................... 8W-40
Intake Air Heater Relays............... 8W-30
Intake Air Temperature Sensor........... 8W-30
Intake Air Temperature/Manifold Absolute
Pressure Sensor..................... 8W-30
Integrated Power Module............... 8W-10
Knock Sensosr........................ 8W-30
License Lamps....................... 8W-51
Lift Pump Motor...................... 8W-30
Line Pressure Sensor................ 8W-30, 31
Lumbar Motors....................... 8W-63
Lumbar Switch....................... 8W-63
DR8W-02 COMPONENT INDEX 8W - 02 - 1

8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Clutch....................8W-10-17, 40
A/C Compressor Clutch Relay.................8W-10-17, 40
A/C-Heater Control....................8W-10-42, 43, 49
Adjustable Pedal Relay....................8W-10-15, 32
Adjustable Pedal Switch..................8W-10-15, 32, 42
Airbag Control Module.....................8W-10-42, 44
Airbag-Passenger On/Off Switch.................8W-10-42
Ambient Temperature Sensor.................8W-10-48, 50
Amplifier Audio..........................8W-10-31
Ashtray Lamp...........................8W-10-35
Auto Shut Down Relay....................8W-10-12, 19
Automatic Day/Night Mirror.................8W-10-41, 48
Auxiliary Battery.........................8W-10-12
Backup Lamp Switch.....................8W-10-44, 49
Battery.............................8W-10-12, 19
Blower Motor............................8W-10-52
Brake Lamp Switch....................8W-10-14, 30, 40
Capacitor..............................8W-10-22
Cigar Lighter Outlet........................8W-10-46
Circuit Breaker...........................8W-10-52
Clearance Lamp No. 1.......................8W-10-35
Clearance Lamp No. 2.......................8W-10-35
Clearance Lamp No. 3.......................8W-10-35
Clearance Lamp No. 4.......................8W-10-35
Clearance Lamp No. 5.......................8W-10-35
Clutch Interlock Brake Switch..................8W-10-37
Coil On Plug No. 1.......................8W-10-20, 23
Coil On Plug No. 2.......................8W-10-21, 22
Coil On Plug No. 3.......................8W-10-20, 23
Coil On Plug No. 4.......................8W-10-21, 22
Coil On Plug No. 5.......................8W-10-20, 23
Coil On Plug No. 6.......................8W-10-21, 22
Coil On Plug No. 7.......................8W-10-20, 23
Coil On Plug No. 8.......................8W-10-21, 22
Compass/Mini-Trip Computer...............8W-10-31, 39, 41
Condenser Fan.........................8W-10-18, 45
Condenser Fan Relay.....................8W-10-18, 45
Controller Antilock Brake.................8W-10-14, 28, 44
Data Link Connector......................8W-10-30, 50
Door Lock Switch-Passenger....................8W-10-41
Driver Door Module....................8W-10-15, 32, 52
Electric Backlight.........................8W-10-49
Electric Brake Provision....................8W-10-12, 19
Engine Control Module................8W-10-12, 26, 38, 40
Fender Lamp-Front Left......................8W-10-35
Fender Lamp-Front Right.....................8W-10-35
Fender Lamp-Rear Left......................8W-10-35
Fender Lamp-Rear Right.....................8W-10-35
Fog Lamp Relay........................8W-10-16, 36
Fog Lamp-Left...........................8W-10-36
Fog Lamp-Right..........................8W-10-36
Front Control Module . 8W-10-13, 26, 29, 30, 32, 33, 34, 36, 47, 48, 50, 51
Fuel Heater............................8W-10-53
Fuel Heater Relay.....................8W-10-18, 40, 53
Fuel Injector No. 1.......................8W-10-23, 24
Fuel Injector No. 2.......................8W-10-21, 22
Fuel Injector No. 3.......................8W-10-23, 24
Fuel Injector No. 4.......................8W-10-21, 22
Fuel Injector No. 5.......................8W-10-23, 24
Fuel Injector No. 6.......................8W-10-21, 22
Fuel Injector No. 7.......................8W-10-23, 24
Fuel Injector No. 8.......................8W-10-21, 22
Fuel Pump Module.......................8W-10-17, 39
Fuel Pump Relay......................8W-10-17, 39, 40
Fuse 1.............................8W-10-12, 19
Fuse 2...........................8W-10-12, 13, 19
Fuse 3.............................8W-10-13, 25
Fuse 4.............................8W-10-13, 25
Fuse 5.......................8W-10-12, 13, 14, 26, 27
Fuse 6...........................8W-10-13, 14, 28
Fuse 7.............................8W-10-14, 28
Fuse 8.............................8W-10-15, 29
Fuse 9.............................8W-10-13, 25
Fuse 10.............................8W-10-13, 25
Fuse 11...........................8W-10-13, 14, 30
Fuse 12...........................8W-10-18, 45, 53
Fuse 13.............................8W-10-13, 30
Fuse 14.............................8W-10-15, 37
Fuse 15...........................8W-10-16, 17, 34
Fuse 16.............................8W-10-17, 40
Fuse 17...........................8W-10-17, 18, 39
Fuse 18.............................8W-10-14, 30
Fuse 19.............................8W-10-14, 31
Fuse 20.............................8W-10-13, 25
Fuse 21.............................8W-10-14, 31
Fuse 22.............................8W-10-14, 31
Fuse 23.............................8W-10-14, 31
Fuse 24.............................8W-10-14, 30Component Page
Fuse 25.............................8W-10-14, 31
Fuse 26...............................8W-10-49
Fuse 27...........................8W-10-17, 18, 43
Fuse 28.............................8W-10-40, 41
Fuse 29...............................8W-10-46
Fuse 32.............................8W-10-17, 34
Fuse 33.............................8W-10-17, 34
Fuse 34.............................8W-10-17, 34
Fuse 35...............................8W-10-44
Fuse 36...............................8W-10-43
Fuse 37...............................8W-10-44
Fuse 38.............................8W-10-43, 44
Fuse 40...........................8W-10-15, 16, 32
Fuse 41.............................8W-10-16, 36
Fuse 42.............................8W-10-14, 32
Fuse 43.............................8W-10-14, 32
Fuse 45...........................8W-10-16, 17, 36
Fuse 46...........................8W-10-15, 16, 33
Fuse 47.............................8W-10-16, 33
Fuse 48.............................8W-10-15, 32
Fuse 49.............................8W-10-12, 19
Fuse 50.............................8W-10-26, 40
Fuse 51...........................8W-10-14, 15, 30
Fuse 52.............................8W-10-43, 44
Fuse 53...............................8W-10-41
Fusible Link............................8W-10-12
G104........................8W-10-27, 29, 47, 48, 53
G201................................8W-10-25
Generator..............................8W-10-12
Headlamp Switch.........................8W-10-36
Headlamp-Left...........................8W-10-51
Headlamp-Right..........................8W-10-51
Heated Mirror Relay......................8W-10-18, 43
Horn Relay...........................8W-10-16, 36
Horn-High Note..........................8W-10-36
Horn-Low Note...........................8W-10-36
Ignition Switch...............8W-10-13, 25, 37, 41, 44, 46, 52
Instrument Cluster............8W-10-14, 25, 30, 31, 41, 46, 52
Integrated Power Module . . 8W-10-3, 4, 12, 13, 14, 15, 16, 17, 18, 19, 25,
26, 27, 28, 29, 30, 31, 32, 33, 34, 36, 37, 39, 40, 41, 42, 43, 44, 45, 46,
47, 48, 49, 50, 51, 53
License Lamp-Left.........................8W-10-34
License Lamp-Right........................8W-10-34
Oxygen Sensor Downstream Relay..............8W-10-12, 19
Park Lamp Relay.......................8W-10-17, 34
Park/Turn Signal Lamp-Left Front..............8W-10-34, 47
Park/Turn Signal Lamp-Right Front.............8W-10-34, 47
Passenger Lumbar Switch.....................8W-10-28
Power Mirror-Left.........................8W-10-43
Power Mirror-Right........................8W-10-43
Power Outlet..........................8W-10-14, 31
Power Outlet-Console.....................8W-10-14, 32
Power Seat Switch-Driver.....................8W-10-28
Power Seat Switch-Passenger...................8W-10-28
Power Window Circuit Breaker..................8W-10-52
Powertrain Control Module . . 8W-10-18, 19, 22, 27, 31, 37, 39, 40, 45, 52
PTCNo.1 .........................8W-10-39, 40, 41
PTCNo.2 .............................8W-10-46
PTCNo.5 .............................8W-10-33
Radio..............................8W-10-30, 46
Rear Window Defogger Relay...................8W-10-49
Seat Belt Tensioner Reducer....................8W-10-46
Seat Heater Interface Module...................8W-10-32
Sentry Key Immobilizer Module..............8W-10-31, 39, 40
Starter Motor..........................8W-10-15, 37
Starter Motor Relay......................8W-10-15, 37
Tail/Stop/Turn Signal Lamp-Left...........8W-10-34, 47, 48, 50
Tail/Stop/Turn Signal Lamp-Right..........8W-10-35, 47, 48, 50
Tailgate Lamp...........................8W-10-34
Trailer Tow Connector.................8W-10-16, 17, 33, 34
Trailer Tow Connector-Add On..........8W-10-14, 31, 33, 34, 48
Trailer Tow Left Turn Relay..................8W-10-16, 33
Trailer Tow Right Turn Relay.................8W-10-16, 33
Transfer Case Control Module...............8W-10-14, 32, 37
Transfer Case Selector Switch...................8W-10-41
Transmission Control Relay................8W-10-13, 26, 27
Transmission Range Sensor................8W-10-38, 44, 49
Transmission Solenoid Assembly.................8W-10-26
Transmission Solenoid/TRS Assembly...........8W-10-27, 44, 49
Underhood Lamp..........................8W-10-30
Vistronic Fan Drive........................8W-10-43
Washer Fluid Level Switch....................8W-10-48
Washer Pump Motor-Front....................8W-10-48
Wiper High/Low Relay.....................8W-10-15, 29
Wiper Motor-Front.......................8W-10-29, 48
Wiper On/Off Relay......................8W-10-15, 29
DR8W-10 POWER DISTRIBUTION 8W - 10 - 1

8W-15 GROUND DISTRIBUTION
Component Page
A/C Compressor Clutch................ 8W-15-5, 8
A/C-Heater Control.................. 8W-15-9, 12
Adjustable Pedal Switch................ 8W-15-12
Airbag Control Module................. 8W-15-15
Amplifier Audio...................... 8W-15-11
Ashtray Lamp....................... 8W-15-11
Automatic Day/Night Mirror.............. 8W-15-9
Auxiliary Battery...................... 8W-15-7
Battery............................. 8W-15-7
Brake Lamp Switch.................... 8W-15-9
Brake Transmission Shift Interlock Solenoid . . 8W-15-14
Center High Mounted Stop Lamp/Cargo Lamp . 8W-15-14
Cigar Lighter Outlet................... 8W-15-12
Clearance Lamp No. 1.................. 8W-15-13
Clearance Lamp No. 2.................. 8W-15-13
Clearance Lamp No. 3.................. 8W-15-13
Clearance Lamp No. 4.................. 8W-15-13
Clearance Lamp No. 5.................. 8W-15-13
Clockspring......................... 8W-15-10
Clutch Interlock Brake Switch............. 8W-15-3
Compass/Mini-Trip Computer.............. 8W-15-9
Condenser Fan........................ 8W-15-4
Cylinder Lock Switch-Driver............. 8W-15-17
Data Link Connector.................... 8W-15-9
Data Link Connector-Engine.............. 8W-15-8
Dome Lamp......................... 8W-15-14
Door Ajar Switch-Driver................ 8W-15-17
Door Ajar Switch-Left Rear.............. 8W-15-16
Door Ajar Switch-Passenger.............. 8W-15-17
Door Ajar Switch-Right Rear............. 8W-15-16
Door Lock Motor/Ajar Switch-Driver........ 8W-15-17
Door Lock Motor/Ajar Switch-Left Rear...... 8W-15-16
Door Lock Motor/Ajar Switch-Passenger..... 8W-15-17
Door Lock Motor/Ajar Switch-Right Rear..... 8W-15-16
Door Lock Switch-Passenger.............. 8W-15-17
Driver Door Module................... 8W-15-18
EGR Solenoid......................... 8W-15-5
Electric Brake Provision................. 8W-15-4
Engine Control Module.................. 8W-15-8
Fender Lamp-Front Left................. 8W-15-2
Fender Lamp-Front Right................ 8W-15-2
Fender Lamp-Rear Left.................. 8W-15-2
Fender Lamp-Rear Right................. 8W-15-2
Fog Lamp-Left........................ 8W-15-3
Fog Lamp-Right....................... 8W-15-3
Fuel Heater.......................... 8W-15-8
Fuel Pump Module..................... 8W-15-4
G100............................... 8W-15-7
G101............................... 8W-15-7
G102............................... 8W-15-7
G104.......................... 8W-15-3, 4, 15
G105............................... 8W-15-7
G107............................. 8W-15-5, 6
G108............................... 8W-15-7
G109............................... 8W-15-7
G114............................... 8W-15-8
G120............................... 8W-15-8
G201............................ 8W-15-9, 10Component Page
G202......................... 8W-15-11, 12, 14
G204.............................. 8W-15-15
G301.............................. 8W-15-16
G302.............................. 8W-15-18
Generator.......................... 8W-15-6, 8
Glove Box Lamp And Switch............. 8W-15-12
Hands Free Module.................... 8W-15-11
Headlamp Switch..................... 8W-15-14
Headlamp-Left........................ 8W-15-3
Headlamp-Right....................... 8W-15-7
Heated Seat Cushion-Driver.............. 8W-15-18
Heated Seat Cushion-Passenger........... 8W-15-19
Heated Seat Switch-Driver............... 8W-15-12
Heated Seat Switch-Passenger............ 8W-15-12
Horn-High Note....................... 8W-15-4
Horn-Low Note........................ 8W-15-4
Ignition Switch....................... 8W-15-10
Instrument Cluster................. 8W-15-10, 14
Intake Air Heater Relay No. 1............. 8W-15-7
Intake Air Heater Relay No. 2............. 8W-15-7
Integrated Power Module............... 8W-15-3, 4
License Lamp-Left..................... 8W-15-2
License Lamp-Right.................... 8W-15-2
Lift Pump Motor....................... 8W-15-8
Natural Vacuum Leak Detection Assembly..... 8W-15-6
Overhead Map/Reading Lamp............ 8W-15-14
Oxygen Sensor 1/1 Upstream.............. 8W-15-6
Oxygen Sensor 1/2 Downstream............ 8W-15-6
Oxygen Sensor 2/1 Upstream.............. 8W-15-6
Oxygen Sensor 2/2 Downstream............ 8W-15-6
Park/Turn Signal Lamp-Left Front.......... 8W-15-4
Park/Turn Signal Lamp-Right Front......... 8W-15-7
Passenger Lumbar Switch............... 8W-15-19
Power Mirror-Left..................... 8W-15-18
Power Mirror-Right.................... 8W-15-18
Power Outlet........................ 8W-15-12
Power Outlet-Console................ 8W-15-15, 19
Power Seat Switch-Driver............... 8W-15-18
Power Seat Switch-Passenger............. 8W-15-19
Power Steering Pressure Switch............ 8W-15-5
Powertrain Control Module............. 8W-15-5, 6
Radio.............................. 8W-15-11
Seat Belt Switch-Driver................. 8W-15-16
Seat Heater Interface Module............. 8W-15-16
Sentry Key Immobilizer Module........... 8W-15-10
Speed Control Servo.................... 8W-15-3
Tail/Stop/Turn Signal Lamp-Left........... 8W-15-2
Tail/Stop/Turn Signal Lamp-Right.......... 8W-15-2
Tailgate Lamp........................ 8W-15-2
Tow/Haul Overdrive Switch............... 8W-15-9
Trailer Tow Connector................... 8W-15-4
Trailer Tow Connector-Add On............. 8W-15-4
Transfer Case Control Module............ 8W-15-15
Transfer Case Selector Switch........... 8W-15-4, 15
Vacuum Pump........................ 8W-15-7
Washer Fluid Level Switch.............. 8W-15-3, 7
Washer Pump Motor-Front............... 8W-15-7
Wiper Motor-Front..................... 8W-15-4
DR8W-15 GROUND DISTRIBUTION 8W - 15 - 1

(6) Remove the wooden dowel rods and rubber
bands from the tappets.
(7) Lubricate the push rods with engine oil and
install in their original location.Verify that they
are seated in the tappets.
(8) Lubricate the valve tips with engine oil and
install the crossheads in their original locations.
(9) Lubricate the crossheads and push rod sockets
with engine oil and install the rocker arms and ped-
estals in their original locations. Tighten bolts to 36
N´m (27 ft. lbs.) torque.
(10)Verify valve lash adjustment (Refer to 9 -
ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
(11) Install the cylinder head cover and reusable
gasket (Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - INSTALLATION).
(12) Install gear housing cover (Refer to 9 -
ENGINE/VALVE TIMING/GEAR HOUSING COVER
- INSTALLATION). Install front crankshaft dust
seal.
(13) Install the crankshaft damper with the speed
indicator ring (Refer to 9 - ENGINE/ENGINE
BLOCK/VIBRATION DAMPER - INSTALLATION).
(14) Install the fan support/hub assembly Refer to
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(15) Install the power steering pump.
(16) Install accessory drive belt tensioner. Torque
bolt to 43 Nm (32 ft. lbs.).
(17) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(18) Install the charge air cooler (with a/c con-
denser and auxiliary transmission oil cooler, if
equipped) and tighten the mounting bolts to 2 N´m
(17 in. lbs.) torque.
(19) Connect charge air cooler inlet and outlet
pipes. Tighten clamps to 11 N´m (95 in. lbs.) torque.
(20) Install the radiator upper support panel.
(21) Close radiator petcock and lower the radiator
into the engine compartment. Tighten the mounting
bolts to 11 N´m (95 in. lbs.) torque.
(22) Raise vehicle on hoist.
(23) Connect radiator lower hose and install
clamp.
(24) Connect transmission auxiliary oil cooler lines
(if equipped).
(25) Lower vehicle.
(26) Install the fan shroud and tighten the mount-
ing screws to 6 N´m (50 in. lbs.) torque.
(27) Install the electronically controlled viscous
fan/drive assembly. Connect harness connector.(Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).(28) Install the coolant recovery and windshield
washer fluid reservoirs to the fan shroud.
(29) Connect the coolant recovery hose to the radi-
ator filler neck.
(30) Add engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(31) Charge A/C system with refrigerant (if A/C
equipped) (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(32) Connect the battery negative cables.
(33) Start engine and check for engine oil and cool-
ant leaks.
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING ROD
BEARING AND CRANKSHAFT JOURNAL
CLEARANCE
(1) Measure the connecting rod bore with bearings
removedand the bolts tightened to 100 N´m (73 ft.
lbs.) torque..
(2) Measure the connecting rod bore with the bear-
ingsinstalledand the bolts tightened to 100 N´m
(73 ft. lbs.) torque.
Measure within 20É arc from each side of the part-
ing line. Also measure 90É from parting line.
Record the smallest and largest diameter.
Measure the diameter of the rod journal at the
location shown (Fig. 63). Calculate the average diam-
eter for each side of the journal.
Determine minimum bearing clearance by calculat-
ing the differance between the smallest connecting
rod bore diameter with the bearing installed and the
average diameter for each side of the crankshaft jour-
nal.
Determine the maximum bearing clearance by cal-
culating the difference between the largest connect-
ing rod bore diameter and the average diameter with
the bearing installed for each side of the crankshaft
journal.
DESCRIPTION MEASUREMENT
CONNECTING ROD
BORE, BEARINGS
REMOVEDMIN. 72.99 mm (2.874
in.)
MAX. 73.01 mm (2.875
in.)
CONNECTING ROD
BORE, BEARINGS
INSTALLEDMIN. 69.05 mm (2.719
in.)
MAX. 69.10 mm (2.720
in.)
9 - 272 ENGINE 5.9L DIESELDR
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

CAUTION: Do not apply more than 138 kPa (20 psi)
air pressure to the charge air cooler system, sever
damage to the charge air cooler system may occur.
(3) Connect a regulated air supply to air fitting on
Tool 9022 Adapter. Set air pressure to a Maximum of
138 kPa (20 psi).
(4) Using soapy water check the rubber sleeves,
charge air cooler and intake manifold for leaks.
REMOVAL
WARNING: IF THE ENGINE WAS JUST TURNED
OFF, THE AIR INTAKE SYSTEM TUBES MAY BE
HOT.
(1) Disconnect the battery negative cables.
(2) Discharge the A/C system (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE) and remove the A/C condenser
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C CONDENSER - REMOVAL) (if A/C
equipped).
(3) Remove the transmission auxiliary cooler
(Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER - REMOVAL).
(4) Remove the boost tubes from the charge air
cooler (Fig. 24).
(5) Remove the charge air cooler bolts. Pivot the
charge air cooler forward and up to remove.
CLEANING
CAUTION: Do not use caustic cleaners to clean the
charge air cooler. Damage to the charge air cooler
will result.
NOTE: If internal debris cannot be removed from
the cooler, the charge air cooler MUST be replaced.
(1) If the engine experiences a turbocharger failure
or any other situation where oil or debris get into the
charge air cooler, the charge air cooler must be
cleaned internally.
(2) Position the charge air cooler so the inlet and
outlet tubes are vertical.
(3) Flush the cooler internally with solvent in the
direction opposite of normal air flow.
(4) Shake the cooler and lightly tap on the end
tanks with a rubber mallet to dislodge trapped
debris.
(5) Continue flushing until all debris or oil are
removed.
(6) Rinse the cooler with hot soapy water to
remove any remaining solvent.
(7) Rinse thoroughly with clean water and blow
dry with compressed air.
INSPECTION
Visually inspect the charge air cooler for cracks,
holes, or damage. Inspect the tubes, fins, and welds
for tears, breaks, or other damage. Replace the
charge air cooler if damage is found.
Pressure test the charge air cooler, using Charge
Air Cooler Tester Kit #3824556. This kit is available
through CumminstService Products. Instructions
are provided with the kit.
INSTALLATION
(1) Position the charge air cooler. Install the bolts
and tighten to 2 N´m (17 in. lbs.) torque.
(2) Install the air intake system tubes to the
charge air cooler. With the clamps in position, tighten
the clamps to 11 N´m (95 in. lbs.) torque.
(3) Install the transmission auxiliary cooler (if
equipped) (Refer to 7 - COOLING/TRANSMISSION/
TRANS COOLER - INSTALLATION).
(4) Install the A/C condenser (if A/C equipped)
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/A/C CONDENSER - INSTALLATION).
Recharge A/C system (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE).
(5) Connect the battery negative cables.
(6) Start engine and check for boost system leaks.
Fig. 24 Air Intake System Tubes
1 - BOLT
2 - CHARGE AIR COOLER
3 - CLAMP
4 - BOOST TUBE
DREXHAUST SYSTEM 11 - 17
CHARGE AIR COOLER AND PLUMBING (Continued)