heater DODGE RAM 2001 Service Repair Manual

(9) If required, adjust spark plugs to specifications.
Install the plugs and tighten to 41 N´m (30 ft. lbs.)
torque.
(10) Install coil wire.
(11) Connect heat indicator sending unit wire.
(12) Connect the heater hoses and bypass hose.
(13) Install distributor cap and wires.
(14) Connect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(15) Install the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(16) Install the generator and drive belt (Refer to 7
- COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION). Tighten generator mounting bolt
to 41 N´m (30 ft. lbs.) torque. Tighten the adjusting
strap bolt to 23 N´m (200 in. lbs.) torque.
(17) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts.
(18) Place the cylinder head cover gaskets in posi-
tion and install cylinder head covers (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(19) Install closed crankcase ventilation system.
(20) Connect the evaporation control system.
(21) Install the air cleaner.
(22) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(23) Connect the negative cable to the battery.
(24) Start engine check for leaks.
CYLINDER HEAD COVER(S)
REMOVAL
NOTE: A steel backed silicon gasket is used with
the cylinder head cover (Fig. 7). This gasket can be
used again.
(1) Disconnect the negative cable from the battery.(2) Disconnect the spark plug wires form the spark
plugs and set aside.
(3) Disconnect closed ventilation system and evap-
oration control system from cylinder head cover.
(4) Remove cylinder head cover and gasket.
CLEANING
Clean cylinder head cover gasket surface.
Clean head rail, if necessary.
INSPECTION
Inspect cover for distortion and straighten, if nec-
essary.
Check the gasket for use in head cover installation.
If damaged, use a new gasket.
INSTALLATION
(1) The cylinder head cover gasket can be used
again. Install the gasket onto the head rail.
(2) Position the cylinder head cover onto the gas-
ket. Tighten the bolts to 11 N´m (95 in. lbs.) torque.
(3) Install closed crankcase ventilation system and
evaporation control system.
(4)
Connect the spark plug wires to the spark plugs.
(5) Connect the negative cable to the battery.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
Both the intake and exhaust valves are made of
steel. The intake valve is 48.768 mm (1.92 inches) in
diameter and the exhaust valve is 41.148 mm (1.62
inches) in diameter and has a 2.032 mm (0.080 inch)
wafer interia welded to the tip for durability. These
valves are not splayed.
STANDARD PROCEDUREÐVALVES, GUIDES
AND SPRINGS
VALVE CLEANING
Clean valves thoroughly. Discard burned, warped,
or cracked valves.
Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner.
VALVE GUIDES
Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 in.), replace the valve.
Measure valve stem guide clearance as follows:
(1) Install Valve Guide Sleeve Tool C-3973 over
valve stem and install valve (Fig. 8). The special
sleeve places the valve at the correct height for
checking with a dial indicator.
Fig. 7 Cylinder Head Cover Gasket
1 - CYLINDER HEAD COVER GASKET
9 - 138 ENGINE 5.9LBR/BE
CYLINDER HEAD (Continued)

(3) If a change in RPMs occurs, the area of the
suspected leak has been found.
(4) Repair as required.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(3) Remove the A/C compressor (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - REMOVAL).
(4) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(5) Remove the accessory drive bracket.
(6) Remove the air cleaner.
(7) Perform the Fuel System Pressure release pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY - STANDARD PROCEDURE). Disconnect the
fuel lines (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(8) Disconnect the accelerator linkage (Refer to 14
- FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - REMOVAL) and if so equipped,
the speed control and transmission kickdown cables.
(9) Remove the return spring.
(10) Remove the distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect the heat indicator sending unit
wire.
(13) Disconnect the heater hoses and bypass hose.
(14) Remove the closed crankcase ventilation and
evaporation control systems.
(15) Remove intake manifold bolts.
(16) Lift the intake manifold and throttle body out
of the engine compartment as an assembly.
(17) Remove and discard the flange side gaskets
and the front and rear end seals.
(18) Remove the throttle body bolts and lift the
throttle body off the intake manifold (Fig. 65). Dis-
card the gasket.
(19) If required, remove the plenum pan and gas-
ket. Discard gasket.
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Clean cylinder block front and rear gasket surfaces
using a suitable 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.
INSTALLATION
(1) If removed, position new plenum gasket and
install plenum pan (Fig. 66).
(2) Tighten plenum pan mounting bolts as follows:
²Step 1. Tighten bolts to 5.4 N´m (48 in. lbs.)
²Step 2. Tighten bolts to 9.5 N´m (84 in. lbs.)
²Step 3. Check all bolts are at 9.5 N´m (84 in.
lbs.)
Fig. 65 Throttle Body Assembly
1 - FUEL RAIL ASSEMBLY
2 - FUEL RAIL MOUNTING BOLTS
3 - FUEL RAIL CONNECTING HOSES
Fig. 66 Plenum Pan Bolt Tightening Sequence
9 - 166 ENGINE 5.9LBR/BE
INTAKE MANIFOLD (Continued)

(9) Install closed crankcase ventilation and evapo-
ration control systems.
(10) Connect the coil wires.
(11) Connect the heat indicator sending unit wire.
(12) Connect the heater hoses and bypass hose.
(13) Install distributor cap and wires.
(14) Hook up the return spring.
(15) Connect the accelerator linkage (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - INSTALLATION) and if so
equipped, the speed control and transmission kick-
down cables.
(16) Install the fuel lines (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE).
(17) Install the accessory drive bracket and A/C
compressor (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/A/C COMPRESSOR -
INSTALLATION).
(18) Install the generator and drive belt (Refer to 7
- COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION). Tighten generator mounting bolt
to 41 N´m (30 ft. lbs.) torque.
(19) Install the air cleaner.
(20) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(21) Connect the negative cable to the battery.
EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifolds (Fig. 70) are constructed of
cast iron and are LOG type with balanced flow. One
exhaust manifold is attached to each cylinder head.
OPERATION
The exhaust manifolds collect the engine exhaust
exiting the combustion chambers, then channels the
exhaust gases to the exhaust pipes attached to the
manifolds.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Raise and support the vehicle.
(3) Remove the bolts and nuts attaching the
exhaust pipe to the engine exhaust manifold.
(4) Lower the vehicle.
(5) Remove the exhaust heat shields.
(6) Remove bolts, nuts and washers attaching
manifold to cylinder head.
(7) Remove manifold from the cylinder head.
CLEANING
Clean mating surfaces on cylinder head and mani-
fold. Wash with solvent and blow dry with com-
pressed air.
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straight edge. Gasket surfaces must be flat
within 0.2 mm per 300 mm (0.008 inch per foot).
INSTALLATION
CAUTION: If the studs came out with the nuts when
removing the engine exhaust manifold, install new
studs. Apply sealer on the coarse thread ends.
Water leaks may develop at the studs if this precau-
tion is not taken.
(1) Position the engine exhaust manifolds on the
two studs located on the cylinder head. Install coni-
cal washers and nuts on these studs (Fig. 71).
(2) Install two bolts and conical washers at the
inner ends of the engine exhaust manifold outboard
arms. Install two bolts WITHOUT washers on the
center arm of engine exhaust manifold (Fig. 71).
Starting at the center arm and working outward,
tighten the bolts and nuts to 34 N´m (25 ft. lbs.)
torque.
(3) Install the exhaust heat shields.
(4) Raise and support the vehicle.
(5) Assemble exhaust pipe to manifold and secure
with bolts, nuts and retainers. Tighten the bolts and
nuts to 34 N´m (25 ft. lbs.) torque.
Fig. 70 Exhaust ManifoldsÐV-8 Gas Engines Typical
1 - EXHAUST MANIFOLD (LEFT)
2 - BOLTS & WASHERS
3 - NUTS & WASHERS
4 - EXHAUST MANIFOLD (RIGHT)
5 - BOLTS & WASHERS
9 - 168 ENGINE 5.9LBR/BE
INTAKE MANIFOLD (Continued)

(6) Remove the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - REMOV-
AL).
(7) Remove the A/C compressor with the lines
attached (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/A/C COMPRESSOR -
REMOVAL). Set aside.
(8) If equipped, remove the condenser (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - REMOVAL).
(9) Remove the washer fluid reservoir bottle (Refer
to 8 - ELECTRICAL/WIPERS/WASHERS -
REMOVAL AND INSTALLATION).
(10) Disconnect the top radiator hose.
(11) Remove the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - REMOVAL).
(12) Remove the fan shroud.
(13) Disconnect the lower radiator hose.
(14) Disconnect the transmission cooler lines.
(15) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(16) Remove the generator with the wire connec-
tions (Refer to 8 - ELECTRICAL/CHARGING/GEN-
ERATOR - REMOVAL).
(17) Remove the air cleaner.
(18) Disconnect the throttle linkage.
(19) Remove throttle body (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/THROTTLE BODY -
REMOVAL).
(20) Remove the upper intake manifold (Refer to 9
- ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL).
(21) Remove the coil assemblies with the ignition
cables.
(22) Disconnect the heater hoses.
(23) Disconnect the power steering hoses, if
equipped.
(24) Perform the Fuel System Pressure release
procedure (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY - STANDARD PROCEDURE). Disconnect
the fuel line (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(25) On Manual Transmission vehicles, remove the
shift lever.
(26) Raise and support the vehicle on a hoist.
(27) Remove the drain plug and drain the engine
oil.
(28) Loosen front engine mount thru-bolt nuts.
(29) Remove the transmission cooler line brackets
from oil pan.
(30) Disconnect exhaust pipe at manifold.
(31) Disconnect the starter wires. Remove starter
motor (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - REMOVAL).
(32) Remove transmission.(33) Lower vehicle.
CAUTION: DO NOT lift the engine by the intake
manifold.
(34) Install an engine lifting fixture.
(35) Remove engine from vehicle and install
engine assembly on a repair stand.
INSTALLATION
(1) Remove engine from the repair stand and posi-
tion in the engine compartment. Position the thru-
bolt into the support cushion brackets.
(2) Install an engine support fixture.
(3) Raise and support the vehicle on a hoist.
(4) Install Transmission.
(5) Install the starter and connect the starter
wires (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(6) Install exhaust pipe to manifold.
(7) Install the transmission cooler line brackets
from oil pan.
(8) Tighten the Front mount thru-bolts and nuts to
102N´m (75 ft. lbs.).
(9) Install the drain plug and tighten to 34 N´m
(25 ft. lbs.) torque.
(10) Prime oil pump by squirting oil in the oil fil-
ter mounting hole and filling the J-trap of the front
timing cover. When oil is running out, install oil filter
that has been filled with oil.
(11) Lower the vehicle.
(12) Remove engine lifting fixture.
(13) On Manual Transmission vehicles, install the
shift lever.
(14) Connect the fuel lines (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE).
(15) Connect the heater hoses.
(16) Install the upper intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).
(17) Install the coil assemblies with the ignition
cables.
(18) Using a new gasket, install throttle body
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE BODY - INSTALLATION).
(19) Connect the throttle linkage.
(20) Install the air cleaner box.
(21) Install the generator and wire connections
(Refer to 8 - ELECTRICAL/CHARGING/GENERA-
TOR - INSTALLATION).
(22) Install the upper crossmember.
(23) Install radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - INSTALLATION).
(24) Connect the lower radiator hose.
9 - 182 ENGINE 8.0LBR/BE
ENGINE 8.0L (Continued)

COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the heat shields (Fig. 8).
(4) Remove the intake manifold-to-generator
bracket support rod. Remove the generator (Refer to
8 - ELECTRICAL/CHARGING/GENERATOR -
REMOVAL).
(5) Remove closed crankcase ventilation system.
(6) Disconnect the evaporation control system.
(7) Remove the air cleaner.
(8) Perform the Fuel System Pressure release pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-ERY - STANDARD PROCEDURE). Disconnect the
fuel line (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY/QUICK CONNECT FITTING - STANDARD
PROCEDURE).
(9) Disconnect accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(10) Remove coil pack and bracket (Fig. 9).
(11) Disconnect the coil wires.
(12) Disconnect heat indicator sending unit wire.
(13) Disconnect heater hoses and bypass hose.
(14) Remove upper intake manifold and throttle
body as an assembly (Refer to 9 - ENGINE/MANI-
FOLDS/INTAKE MANIFOLD - REMOVAL).
(15) Remove cylinder head covers and gaskets
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(16) Remove the EGR tube. Discard the gasket, for
right side only.
(17) Remove lower intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL). Discard the flange side gaskets and the
front and rear cross-over gaskets.
(18) Disconnect exhaust pipe from exhaust mani-
fold.
(19) Remove exhaust manifolds and gaskets (Refer
to 9 - ENGINE/MANIFOLDS/EXHAUST MANIFOLD
- REMOVAL).
(20) Remove rocker arm assemblies and push rods
(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
Fig. 8 Spark Plug Wire Heat Shields (Left Side
Shown)
1 - EXHAUST MANIFOLD
2 - HEAT SHIELD
Fig. 9 Coil Pack and Bracket
1 - COIL PACKS AND BRACKET
2 - MOUNTING BOLTS (4)
9 - 192 ENGINE 8.0LBR/BE
CYLINDER HEAD (Continued)

ARM / ADJUSTER ASSY - REMOVAL). Identify to
ensure installation in original locations.
(21) Remove the head bolts from each cylinder
head and remove cylinder heads. Discard the cylin-
der head gasket.
(22) Remove spark plugs.
CLEANING
Clean all surfaces of cylinder block and cylinder
heads. Be sure material does not fall into the lifters
and surrounding valley.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
Clean the exhaust manifold to cylinder head mat-
ing areas.
INSPECTION
Inspect all surfaces with a straightedge if there is
any reason to suspect leakage. The out-of-flatness
specifications are 0.0007 mm/mm (0.0004 inch/inch),
0.127 mm/152 mm (0.005 inch/6 inches) any direction
or 0.254 mm (0.010 inch) overall across head. If
exceeded, either replace head or lightly machine the
head surface.
The cylinder head surface finish should be
1.78-4.57 microns (15-80 microinches).
Inspect push rods. Replace worn or bent rods.
Inspect rocker arms. Replace if worn or scored.
INSTALLATION
(1) Position the new cylinder head gaskets onto
the cylinder block.
(2) Position the cylinder heads onto head gaskets
and cylinder block.
(3) Tighten the cylinder head bolts in two steps
(Fig. 10):
²Step 1ÐTighten all cylinder head bolts, in
sequence, to 58 N´m (43 ft. lbs.) torque.
²Step 2ÐTighten all cylinder head bolts, in
sequence, to 143 N´m (105 ft. lbs.) torque.
²
CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
TDC. Contact between the valves and piston could
occur.
(4) Install push rods and rocker arm assemblies in
their original position (Refer to 9 - ENGINE/CYLIN-
DER HEAD/ROCKER ARM / ADJUSTER ASSY -
INSTALLATION).
(5) Install lower intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).(6) Install the upper intake manifold onto the
lower intake manifold (Refer to 9 - ENGINE/MANI-
FOLDS/INTAKE MANIFOLD - INSTALLATION).
(7) Install the exhaust manifolds and new gaskets
(Refer to 9 - ENGINE/MANIFOLDS/EXHAUST
MANIFOLD - INSTALLATION).
(8) Install exhaust pipe to the exhaust manifold.
Tighten the bolts to 34 n´m (25 ft. lbs.) torque.
(9) Using a new gasket, position the EGR tube to
the intake manifold and the exhaust manifold.
Tighten the EGR tube nut to 34 N´m (25 ft. lbs.)
torque. Tighten the bolts to 20 N´m (174 in. lbs.)
torque.
(10) Install the heat shields and the washers.
Make sure that heat shields tabs hook over the
exhaust gasket.Tighten the nuts to 15 N´m (132 in.
lbs.) torque.
(11) Adjust and Install the spark plugs (Refer to 8
- ELECTRICAL/IGNITION CONTROL/SPARK
PLUG - INSTALLATION).
(12) Install coil packs and bracket. Tighten the
bracket bolts to 21 N´m (190 in. lbs.) torque. Connect
the coil wires.
(13) Connect heat indicator sending unit wire.
(14) Connect the heater hoses and bypass hose.
(15) Connect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(16) Install the fuel line (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE).
(17) Install the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - INSTALLATION)
and drive belt (Refer to 7 - COOLING/ACCESSORY
DRIVE/DRIVE BELTS - INSTALLATION).
(18) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts to 41 N´m (30
ft. lbs.) torque.
(19) The cylinder head cover gasket can be used
again. Install the gasket onto the head rail.For the
left side the number tab is at the front of
engine with the number up. For the right side
the number tab is at the rear of engine with the
number up.
Fig. 10 Cylinder Head Bolt Tightening Sequence
BR/BEENGINE 8.0L 9 - 193
CYLINDER HEAD (Continued)

(6) Remove the air cleaner cover and filter.
Remove the air cleaner housing (Fig. 70). Discard the
gasket.
(7) Perform the Fuel System Pressure release pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY - STANDARD PROCEDURE). Disconnect the
fuel lines (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(8) Disconnect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(9) Remove the coil assemblies with the ignition
wires.
(10) Disconnect the vacuum lines.
(11) Disconnect the heater hoses and bypass hose.
(12) Remove the closed crankcase ventilation and
evaporation control systems.
(13) Remove the throttle body bolts and lift the
throttle body off the upper intake manifold (Fig. 71).
Discard the gasket.
(14) Remove upper intake manifold bolts.
(15) Lift the upper intake manifold out of the
engine compartment (Fig. 71). Discard the gasket.
(16) Remove the lower intake manifold bolts and
remove the manifold (Fig. 72).
(17) Discard the lower intake manifold gaskets
(Fig. 73).
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Clean cylinder block front and rear gasket surfaces
using a suitable 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.
INSTALLATION
(1) Install the intake manifold side gaskets. Be
sure that the locator dowels are positioned in the
head (Fig. 74).
(2) Insert MopartGEN II Silicone Rubber Adhe-
sive Sealant, or equivalent, into the four corner joints
an excessive amount of sealant is not required to
ensure a leak proof seal. However, an excessive
amount of sealant may reduce the effectiveness of
the flange gasket. The sealant should be approxi-
mately 5 mm (0.2 in.) in diameter. (Fig. 73).
Fig. 70 Air Intake Housing
1 - AIR INTAKE HOUSING
Fig. 71 Upper Intake Manifold and Throttle Body
1 - UPPER INTAKE MANIFOLD
2 - THROTTLE BODY (MPI)
3 - LOWER INTAKE MANIFOLD
Fig. 72 Lower Intake Manifold
BR/BEENGINE 8.0L 9 - 223
INTAKE MANIFOLD (Continued)

(3) Position the cross-over gaskets and press firmly
onto the block (Fig. 73).BE SURE THE BLOCK IS
OIL FREE..
(4) The lower intake manifold MUST be installed
within 3 minutes of sealant application. Carefully
lower intake manifold into position on the cylinder
block and heads. After intake manifold is in place,
inspect to make sure seals and gaskets are in place.
Finger start all the lower intake bolts.
(5) Tighten the lower intake manifold bolts in
sequence to 54 N´m (40 ft. lbs.) torque (Fig. 72).Recheck all bolts are tightened to 54 N´m (40 ft. lbs.)
torque.
(6) Using a new gasket, position the upper intake
manifold onto the lower intake manifold.
(7) Finger start all bolts, alternate one side to the
other.
(8) Tighten upper intake manifold bolts in
sequence to 22 N´m (16 ft. lbs.) torque (Fig. 71).
(9) Using a new gasket, install the throttle body
onto the upper intake manifold. Tighten the bolts to
23 N´m (200 in. lbs.) torque.
(10) Install closed crankcase ventilation and evap-
oration control systems.
(11) Connect the heater hoses and bypass hose.
(12) Connect the vacuum lines.
(13) Install the coil assemblies and the ignition
wires.
(14) Connect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(15) Install the fuel lines (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE).
(16) Using a new gasket, install the air cleaner
housing. Tighten the nuts to 11 N´m (96 in. lbs.)
torque. Install the air cleaner filter and cover.
(17) Install the A/C compressor (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - INSTALLATION). Position the com-
pressor brace and install the bolts. Tighten the brace
bolts to 41 N´m (30 ft. lbs.) torque.
(18) Install the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - INSTALLATION).
Position the generator brace and install the bolts.
Tighten the brace bolts to 41 N´m (30 ft. lbs.) torque.
(19) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(20) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(21) Connect the negative cable to the battery.
(22) Start engine check for leaks.
EXHAUST MANIFOLD
DESCRIPTION
Engine exhaust manifolds (Fig. 75) are made of
high molybdenum ductile cast iron. A special ribbed
design helps control permanent dimensional changes
during heat cycles.
OPERATION
The exhaust manifolds collect the engine exhaust
exiting the combustion chambers, then channels the
Fig. 73 Lower Intake Manifold Gaskets
1 - INTAKE MANIFOLD GASKET
2 - SEALANT
3 - CROSS-OVER GASKETS
4 - SEALANT
5 - LOCATOR DOWELS
Fig. 74 Intake Manifold Flange
1 - LOCATOR DOWELS
2 - INTAKE MANIFOLD GASKETS
3 - LOCATOR DOWELS
9 - 224 ENGINE 8.0LBR/BE
INTAKE MANIFOLD (Continued)

EXCESSIVE BLACK SMOKE
POSSIBLE CAUSE CORRECTION
Raw fuel in intake manifold. Fuel injectors leaking on engine shutdown. Do Fuel
Injector Test (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/FUEL INJECTOR - DIAGNOSIS AND
TESTING).
Static timing not correct. A DTC should have been set. If so, refer to Powertrain
Diagnostic Procedures Information. Also (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJECTION
PUMP - DIAGNOSIS AND TESTING).
Turbocharger air intake restriction. Remove restriction.
Turbocharger damaged. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - INSPECTION).
Turbocharger has excess build up on compressor
wheel and/or diffuser vanes.(Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - CLEANING).
Turbocharger wheel clearance out of specification. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - INSPECTION).
EXCESSIVE WHITE SMOKE
POSSIBLE CAUSE CORRECTION
Air in fuel supply: Possible leak in fuel supply side
(between transfer pump and fuel tank module).(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL
TRANSFER PUMP - DIAGNOSIS AND TESTING).
Coolant leaking into combustion chamber. Do pressure test of cooling system (Refer to 7 -
COOLING - DIAGNOSIS AND TESTING).
Diagnostic Trouble Codes (DTC's) active or multiple,
intermittent DTC's.Refer to Powertrain Diagnostic Procedures Information.
In very cold ambient temperatures, engine block heater
is malfunctioning (if equipped).(Refer to 7 - COOLING/ENGINE/ENGINE BLOCK
HEATER - REMOVAL).
Engine coolant temperature sensor malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information. Also check
thermostat operation (Refer to 7 - COOLING/ENGINE/
ENGINE COOLANT THERMOSTAT - DIAGNOSIS AND
TESTING).
Engine Control Module (ECM) not calibrated or has
incorrect calibration.A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Fuel filter plugged. Perform Fuel Pressure Drop Test (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL TRANSFER PUMP -
DIAGNOSIS AND TESTING).
Fuel grade not correct or fuel quality is poor. Temporarily change fuel brands and note condition.
Change brand if necessary.
Fuel heater element or fuel heater temperature sensor
malfunctioning. This will cause wax type build-up in fuel
filter.Refer to Fuel Heater Testing (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL HEATER -
DIAGNOSIS AND TESTING).
Fuel injector malfunctioning. A DTC should have been set. Perform9Cylinder
Balance Test9using DRB scan tool to isolate individual
cylinders. Also refer to Powertrain Diagnostic
Procedures Information and, (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/FUEL INJECTOR -
DIAGNOSIS AND TESTING).
Fuel injector hold-downs loose. Torque to specifications.
BR/BEENGINE 5.9L DIESEL 9 - 235
ENGINE 5.9L DIESEL (Continued)

EXCESSIVE WHITE SMOKE
POSSIBLE CAUSE CORRECTION
Fuel injector protrusion not correct. Check washer (shim) at bottom of fuel injector for
correct thickness. (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/FUEL INJECTOR - INSTALLATION)
Fuel injection pump malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Fuel supply side restriction to transfer pump. Refer to Fuel Transfer Pump Pressure (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL TRANSFER
PUMP - DIAGNOSIS AND TESTING)
Fuel transfer (lift) pump malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information. Also refer to Fuel
Transfer Pump Pressure Testing (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL TRANSFER PUMP -
DIAGNOSIS AND TESTING).
Intake/Exhaust valve adjustments not correct (too tight). (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/
EXHAUST VALVES & SEATS - STANDARD
PROCEDURE).
Intake manifold air temperature sensor malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Intake manifold heater circuit not functioning correctly in
cold weather.A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information. Also check heater
elements for correct operation.
Intake manifold heater elements not functioning
correctly in cold weather.A diagnostic trouble code WILL NOT BE SET if heater
elements are malfunctioning. Refer to NTC tests in
Powertrain Diagnostic Procedures Information.
Internal engine damage (scuffed cylinder). Analyze engine oil and inspect oil filter to locate area of
probable damage.
Restriction in fuel supply side of fuel system. Refer to Fuel Transfer Pump Pressure Testing (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL
TRANSFER PUMP - DIAGNOSIS AND TESTING).
Static timing incorrect. A DTC should have been set. If so, (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJECTION
PUMP - DIAGNOSIS AND TESTING).
EXCESSIVE BLUE SMOKE
POSSIBLE CAUSE CORRECTION
Dirty air cleaner or restricted turbocharger intake duct. Check Filter MinderTat air filter housing. (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
ELEMENT - REMOVAL).
Air leak in boost system between turbocharger
compressor outlet and intake manifold.Service air charge system..
Obstruction in exhaust manifold. Remove exhaust manifold and inspect for blockage
(Refer to 9 - ENGINE/MANIFOLDS/EXHAUST
MANIFOLD - REMOVAL).
Restricted turbocharger drain tube. Remove turbocharger drain tube and remove
obstruction.
Crankcase ventilation system plugged. Inspect crankcase breather and vent tube for sludge
formation or obstructions.
9 - 236 ENGINE 5.9L DIESELBR/BE
ENGINE 5.9L DIESEL (Continued)