Temperature DODGE RAM 2001 Service Repair Manual

POWERTRAIN CONTROL MODULE C2 (DIESEL) - BLACK 32 WAY
CAV CIRCUIT FUNCTION
9- -
10 K20 18DG GENERATOR FIELD
11 K54 18OR/BK (A/T) TORQUE CONVERTER CLUTCH SOLENOID CONTROL
12 - -
13 - -
14 - -
15 - -
16 - -
17 - -
18 - --
19 - -
20 - -
21 T60 18BR (A/T) 3-4 SHIFT SOLENOID CONTROL
22 - -
23 - -
24 - -
25 T13 18DB/BK OUTPUT SPEED SENSOR GROUND
26 - -
27 G7 18WT/OR (A/T) VEHICLE SPEED SENSOR SIGNAL
28 T14 18LG/BK OUTPUT SPEED SENSOR SIGNAL
29 T25 18LG/WT (A/T) GOVERNOR PRESSURE SENSOR SIGNAL
30 K30 18PK (A/T) TRANSMISSION CONTROL RELAY CONTROL
31 K7 18OR (A/T) 5V SUPPLY
32 - -
POWERTRAIN CONTROL MODULE C2 (GAS) - BLACK 32 WAY
CAV CIRCUIT FUNCTION
1 T54 18VT (A/T) TRANSMISSION TEMPERATURE SENSOR SIGNAL
2 K26 18VT/TN (5.2L/5.9L/8.0L) FUEL INJECTOR NO. 7 DRIVER
3 K115 18TN/BK (8.0L) FUEL INJECTOR NO. 9 DRIVER
4 K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER
5 K13 18YL/WT FUEL INJECTOR NO. 3 DRIVER
6 K38 18GY FUEL INJECTOR NO. 5 DRIVER
7- -
8 K88 18VT/WT (A/T) GOVERNOR PRESSURE SOLENOID CONTROL
9- -
10 K20 18DG GENERATOR FIELD
11 K54 18OR/BK TORQUE CONVERTER CLUTCH SOLENOID CONTROL
12 K58 18BR/DB FUEL INJECTOR NO. 6 DRIVER
13 K28 18GY/LB (5.2L/5.9L/8.0L) FUEL INJECTOR NO. 8 DRIVER
14 K116 18WT (8.0L) FUEL INJECTOR NO. 10 DRIVER
15 K12 18TN FUEL INJECTOR NO. 2 DRIVER
16 K14 18LB/BR FUEL INJECTOR NO. 4 DRIVER
17 - -
18 - -
19 - -
20 - -
21 T60 18BR (A/T) 3-4 SHIFT SOLENOID CONTROL
22 - -
23 G60 18GY/OR ENGINE OIL PRESSURE SENSOR SIGNAL
24 - -
8W - 80 - 68 8W-80 CONNECTOR PIN-OUTSBR/BE

POWERTRAIN CONTROL MODULE C2 (GAS) - BLACK 32 WAY
CAV CIRCUIT FUNCTION
25 T13 18DB/BK (A/T) OUTPUT SPEED SENSOR GROUND
26 - -
27 G7 18WT/OR (A/T) VEHICLE SPEED SENSOR SIGNAL
28 T14 18LG/BK (A/T) OUTPUT SPEED SENSOR SIGNAL
29 T25 18LG/WT (A/T) GOVERNOR PRESSURE SENSOR SIGNAL
30 K30 18PK (A/T) TRANSMISSION CONTROL RELAY CONTROL
31 K7 18OR (A/T) 5V SUPPLY
32 - -
POWERTRAIN CONTROL MODULE C3 (DIESEL) - BLACK 32 WAY
CAV CIRCUIT FUNCTION
1 C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
2- -
3 K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL
4 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
5 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
6- -
7- -
8- -
9- -
10 - -
11 V32 18YL/RD SPEED CONTROL SUPPLY
12 A142 14DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
13 T6 18OR/WT (A/T) OVERDRIVE OFF SWITCH SENSE
14 - -
15 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
16 - -
17 - -
18 - -
19 - -
20 - -
21 - -
22 C20 18BR A/C SWITCH SENSE
23 C90 18LG/WT A/C SELECT INPUT
24 V40 18WT/PK BRAKE SWITCH SENSE
25 T125 18DB GENERATOR SOURCE
26 K226 18DB/WT FUEL LEVEL SENSOR SIGNAL
27 D21 18PK/DB SCI TRANSMIT
28 D2 18WT/BK CCD BUS(-)
29 D220 18WT/VT SCI RECEIVE
30 D1 18VT/BR CCD BUS(+)
31 - -
32 V37 18RD/LG SPEED CONTROL SWITCH SIGNAL
BR/BE8W-80 CONNECTOR PIN-OUTS 8W - 80 - 69

POWERTRAIN CONTROL MODULE C3 (GAS) - BLACK 32 WAY
CAV CIRCUIT FUNCTION
1 C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
2- -
3 K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL
4 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
5 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
6- -
7- -
8 K199 18BR/VT (CALIFORNIA) OXYGEN SENSOR 1/1 HEATER CONTROL
9 K145 20DG/PK (CALIFORNIA) OXYGEN SENSOR DOWNSTREAM RELAY CONTROL
10 K106 18WT/DG LEAK DETECTION PUMP SOLENOID CONTROL
11 V32 18YL/RD SPEED CONTROL SUPPLY
12 A142 14DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
13 T6 18OR/WT (A/T) OVERDRIVE OFF SWITCH SENSE
14 K107 18OR LEAK DETECTION PUMP SWITCH SENSE
15 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
16 K299 18BR.WT OXYGEN SENSOR 2/1 HEATER CONTROL
17 - -
18 - -
19 K31 18BR/WT FUEL PUMP RELAY CONTROL
20 K52 18PK/WT EVAPORATIVE EMISSION SOLENOID CONTROL
21 - -
22 C20 18BR A/C SWITCH SENSE
23 C90 18LG/WT A/C SELECT INPUT
24 V40 18WT/PK BRAKE SWITCH SENSE
25 T125 18DB GENERATOR SOURCE
26 K226 18DB/WT FUEL LEVEL SENSOR SIGNAL
27 D21 18PK/DB SCI TRANSMIT
28 D2 18WT/BK CCD BUS (-)
29 D20 18DG SCI RECEIVE
30 D1 18VT/BR CCD BUS (+)
31 - -
32 V37 18RD/LG SPEED CONTROL SWITCH SIGNAL
RADIO C1 - GRAY 7 WAY
CAV CIRCUIT FUNCTION
1- -
2 X55 18BR/RD LEFT FRONT DOOR SPEAKER (-)
3 X56 18DB/RD RIGHT FRONT DOOR SPEAKER (-)
4 E17 18YL/BK DAY BRIGHTNESS SENSE
5 E2 22OR PANEL LAMPS FEED
6 X12 16RD/WT FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
7 M1 22PK FUSED B(+)
8W - 80 - 70 8W-80 CONNECTOR PIN-OUTSBR/BE

SEAT BELT SWITCH (STANDARD CAB) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 G10 20LG/RD SEAT BELT SWITCH SENSE
2 Z2 20BK/LG GROUND
SEAT HEAT INTERFACE MODULE - 14 WAY
CAV CIRCUIT FUNCTION
1 P7 20LB/BK DRIVER HEATED SEAT SWITCH
2 P144 20BK/WT SEAT TEMPERATURE 5V SUPPLY
3 P130 16TN RIGHT SEAT HEATER B(+) DRIVER
4 F235 16RD B(+) TO HEATED SEAT MODULE
5 P131 16RD/DG LEFT SEAT HEATER B(+) DRIVER
6 F235 16RD B(+) TO HEATED SEAT MODULE
7 P142 22DB RIGHT SEAT TEMPERATURE SENSOR INPUT
8 P141 20TN/LB LEFT SEAT TEMPERATURE SENSOR INPUT
9 P8 20LB/WT PASSENGER HEATED SEAT SWITCH
10 P138 20VT/LG RIGHT SEAT LOW HEAT LED DRIVER
11 P140 20VT/BK RIGHT SEAT HIGH HEAT LED DRIVER
12 P137 20DG LEFT SEAT LOW HEAT LED DRIVER
13 Z2 18BK/LG GROUND
14 P139 20WT LEFT SEAT HIGH HEAT LED DRIVER
SPEED CONTROL SERVO - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 V36 20TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
2 V35 20LG/RD SPEED CONTROL VENT SOLENOID CONTROL
3 V30 20DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT
4 Z1 20BK GROUND
TAILGATE LAMP (DUAL REAR WHEELS) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z13 18BK GROUND
2 L7 18BK/YL HEADLAMP SWITCH OUTPUT
THROTTLE POSITION SENSOR (GAS)-3WAY
CAV CIRCUIT FUNCTION
1 K6 20VT/WT 5V OUTPUT
2 K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL
3 K4 20BK/LB SENSOR GROUND
8W - 80 - 76 8W-80 CONNECTOR PIN-OUTSBR/BE

TRAILER TOW CONNECTOR - 10 WAY
CAV CIRCUIT FUNCTION
1- -
2 L62 16BR/RD RIGHT TURN SIGNAL
3 L1 18VT/BK BACK-UP LAMP FEED
4 A6 14RD/OR FUSED B(+)
5 L76 14BK/OR TRAILER TOW RELAY OUTPUT
6- -
7 B40 14LB TRAILER TOW BRAKE B(+)
8 Z13 14BK GROUND
9 Z13 14BK GROUND
10 L63 16DG/RD LEFT TURN SIGNAL
TRANSMISSION SOLENOID ASSEMBLY-8WAY
CAV CIRCUIT FUNCTION
1 T16 18RD TRANSMISSION CONTROL RELAY OUTPUT
2 K7 18OR 5V SUPPLY
3 K4 18BK/LB SENSOR GROUND
4 T25 18LG/WT GOVERNOR PRESSURE SENSOR SIGNAL
5 K88 18VT/WT GOVERNOR PRESSURE SOLENOID CONTROL
6 T60 18BR 3-4 SHIFT SOLENOID CONTROL
7 K54 18OR/BK TORQUE CONVERTER CLUTCH SOLENOID CONTROL
8 T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL
UNDERHOOD LAMP - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
2 M1 20PK FUSED B(+)
WASHER FLUID LEVEL SWITCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 G29 18BK/WT WASHER FLUID SWITCH SENSE
2 Z1 18BK GROUND
BR/BE8W-80 CONNECTOR PIN-OUTS 8W - 80 - 77

8W-90 CONNECTOR/GROUND LOCATIONS
TABLE OF CONTENTS
page
CONNECTOR/GROUND LOCATIONS
DESCRIPTION............................1
CONNECTOR/GROUND
LOCATIONS
DESCRIPTION
This section provides illustrations identifying con-
nector and ground locations in the vehicle. A connec-tor and ground index is provided. Use the wiring
diagrams in each section for connector and ground
identification. Refer to the index for the proper figure
number. For items that are not shown in this section
N/S is placed in the Fig. column.
Connector Name/Number Color Location Fig.
4WD Switch BK On Front Axle N/S
A/C Compressor Clutch BK Rear of A/C Compressor 4,5,6,8
A/C Heater Control BK Center of Instrument Panel 25
A/C Heater Temperature Select NAT Center of Instrument Panel 25
A/C High Pressure Switch BK At A/C Compressor 4,5,6,8
A/C Low Pressure Switch BK Top of A/C Accumulator 1,2
Accelerator Pedal Position Sensor (Diesel) Left Front of Engine 10,11
Aftermarket Trailer Tow Connector Rear of Vehicle N/S
Airbag Control Module Center of I.P. at Airbag Control
Module23
Ambient Temperature Sensor BK Radiator Left Support N/S
Ash Receiver Lamp Center of Instrument Panel 26
Back-up Lamp Switch BK Top of Transmission 13
Battery Temperature Sensor BK Below Battery Tray 16
Blend Door Actuator Center of Instrument Panel N/S
Blower Motor BK Bottom Right of Instrument Panel 23
Blower Motor Resistor Block BK Bottom Right of Instrument Panel 26
Brake Lamp Switch Brake Pedal Arm 23,24
Brake Pressure Switch At Master Cylinder 14
Bypass Jumper GN Top Of Clutch Pedal 27
C105 Rear of Front Bumper N/S
C106 BK Rear of Front Bumper 17
C114 BK Radiator Left Support 15
C125 (Diesel) BK Left Rear of Engine Compartment 2
C126 (Diesel) GY Left Rear of Engine Compartment 2
C129 BK Above Left Front Body Cushion 15,22
C130 At Power Distribution Center 1,2
C134 BK Left Cowl 23,25,27
BR/BE8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 1

Connector Name/Number Color Location Fig.
Cummins Bus (-) Left Front of Engine 10
Cup Holder Lamp Center of Instrument Panel 23,26
Data Link Connector BK Left Bottom of Instrument Panel 23,24
Day/Night Mirror BK Day/Night Mirror N/S
Daytime Running Lamp Module BK Left Fender Side Shield 14
Dome Lamp Rear of Cab 18
Driver Airbag BK Steering Wheel N/S
Driver Door Arm/Disarm Switch BK In Door 19
Driver Door Jamb Switch NAT Door Jamb 19
Driver Door Lock Motor BK In Door 19
Driver Door Window/Lock Switch BL In Door 19
Driver Heated Seat Module BL Under Seat N/S
Driver Heated Seat Switch RD Center of Instrument Panel N/S
Driver Lumbar Motor Under Seat N/S
Driver Power Seat Front Vertical Motor BK Under Seat N/S
Driver Power Seat Horizontal Motor BK Under Seat N/S
Driver Power Seat Rear Vertical Motor Under Seat N/S
Driver Power Seat Switch At Seat N/S
Driver Power Window Motor In Door 19
Duty Cycle EVAP/Purge Solenoid BK Right Fender Side Shield 17
Electric Brake Provision Bottom Left of Instrument Panel N/S
Engine Control Module (Diesel) Left Side Engine 12
Engine Coolant Temperature Sensor (Diesel) BK Left Front of Cylinder Head
(Diesel)10
Engine Coolant Temperature Sensor (Gas) BK On Thermostat Housing 3,6
Engine Oil Pressure Sensor (V6, V8) BK Near Distributor 3
Engine Oil Pressure Sensor (V10) Near Oil Filter 6
Engine Oil Pressure Sensor (Diesel) Left Side of Engine 12
Fuel Heater (Diesel) Left Side of Engine 10
Fuel Injection Pump (Diesel) Left Side of Engine, Below ECM 10
Fuel Injector No.1 BK At Fuel Injector 4,5
Fuel Injector No. 2 BK At Fuel Injector 4,5,6
Fuel Injector No. 3 BK At Fuel Injector 4,5,6
Fuel Injector No. 4 BK At Fuel Injector 4,5,6
Fuel Injector No. 5 BK At Fuel Injector 4,5,6
Fuel Injector No. 6 BK At Fuel Injector 4,5,6
Fuel Injector No. 7 BK At Fuel Injector 4,6
Fuel Injector No. 8 BK At Fuel Injector 4,6
Fuel Injector No. 9 BK At Fuel Injector 6
Fuel Injector No. 10 BK At Fuel Injector 6
Fuel Pump Module LTGY At Frame Rail 22
Fuel Transfer Pump (Diesel) Left Rear of Engine Bottom of
Pump10
BR/BE8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 3
CONNECTOR/GROUND LOCATIONS (Continued)

Connector Name/Number Color Location Fig.
G100 Left Fender Side Shield 16
G101 Left Fender Side Shield 16
G102 Left Fender Side Shield (RWAL
Ground)N/S
G103 Near T/O for Wiper Motor 14
G105 Front of Engine (Engine Ground) 4,5,6,9
G107 (Diesel) Left Rear of Engine 10
G113 (Diesel) Primary Battery Engine Ground N/S
G114 Battery Engine Ground N/S
G115 (Diesel) Primary Battery Body Ground N/S
G116 Battery Frame Ground N/S
G117 (Diesel) Auxilary Battery Engine Ground N/S
G118 (Diesel) Primary Frame Ground N/S
G120 (Diesel) Auxilary Battery Body Ground N/S
G200 Left Cowl 24
G201 Instrument Panel Right Center
Support23,25
G300 Left Lower Cowl 20
G301 Below Left Rear Speaker 18
G302 At Overhead Console 20
Generator BK Front of Engine 7,8
Glove Box Lamp At Glove Box 23
Headlamp Switch C1 BK Left Side of Instrument Panel 23,26
Headlamp Switch C2 Left Side of Instrument Panel 23,26
Heated Mirror Switch Center of Instrument Panel 25
High Note Horn BK Front Bumper Right Support 17
Idle Air Control Motor BK On Throttle Body 9
Ignition Coil GY Right Front of Engine 4,5,9
Ignition Coil 4 Pack BK Right Side of Engine 9
Ignition Coil 6 Pack BK Right Side of Engine 9
Ignition Switch C1 Steering Column 24
Ignition Switch C2 Steering Column 24
Instrument Cluster C1 Rear of Instrument Cluster 23
Instrument Cluster C2 Rear of Instrument Cluster 23
Intake Air Heater Relay Left Fender Side Shield 16
Intake Air Temperature Sensor (Diesel) Left Rear of Engine 10
Intake Air Temperature Sensor (Gas) GY On Intake Manifold 4,5,6
Joint Connector No. 1 In Power Distribution Center N/S
Joint Connector No. 2 In Power Distribution Center N/S
Joint Connector No. 3 Front Bumper Right support 17
Joint Connector No. 4 Left Front Engine Compartment 16
Joint Connector No. 5 NAT Left Side of Instrument Panel 24
Joint Connector No. 6 NAT Left Side of Instrument Pane 24
8W - 90 - 4 8W-90 CONNECTOR/GROUND LOCATIONSBR/BE
CONNECTOR/GROUND LOCATIONS (Continued)

DIAGNOSIS AND TESTINGÐCYLINDER
COMPRESSION PRESSURE
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise, the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Clean the spark plug recesses with compressed
air.
(2) Remove the spark plugs (Refer to 8 - ELEC-
TRICAL/IGNITION CONTROL/SPARK PLUG -
REMOVAL).
(3) Secure the throttle in the wide-open position.
(4) Disconnect the ignition coil.
(5) Insert a compression pressure gauge and rotate
the engine with the engine starter motor for three
revolutions.
(6) Record the compression pressure on the third
revolution. Continue the test for the remaining cylin-
ders.
(Refer to 9 - ENGINE - SPECIFICATIONS) for the
correct engine compression pressures.
DIAGNOSIS AND TESTINGÐCYLINDER
COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing)
²Leaks between adjacent cylinders or into water
jacket²Any causes for combustion/compression pressure
loss
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM HOT COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn OFF the
engine.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum and 552 kPa (80 psi) recom-
mended.
Perform the test procedure on each cylinder accord-
ing to the tester manufacturer's instructions. While
testing, listen for pressurized air escaping through
the throttle body, tailpipe or oil filler cap opening.
Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
Refer to CYLINDER COMBUSTION PRESSURE
LEAKAGE DIAGNOSIS CHART below
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
AIR ESCAPES THROUGH
THROTTLE BODYIntake valve bent, burnt, or not
seated properlyInspect valve and valve seat.
Reface or replace, as necessary
AIR ESCAPES THROUGH
TAILPIPEExhaust valve bent, burnt, or not
seated properlyInspect valve and valve seat.
Reface or replace, as necessary
AIR ESCAPES THROUGH
RADIATORHead gasket leaking or cracked
cylinder head or blockRemove cylinder head and inspect.
Replace defective part
MORE THAN 50% LEAKAGE
FROM ADJACENT CYLINDERSHead gasket leaking or crack in
cylinder head or block between
adjacent cylindersRemove cylinder head and inspect.
Replace gasket, head, or block as
necessary
MORE THAN 25% LEAKAGE AND
AIR ESCAPES THROUGH OIL
FILLER CAP OPENING ONLYStuck or broken piston rings;
cracked piston; worn rings and/or
cylinder wallInspect for broken rings or piston.
Measure ring gap and cylinder
diameter, taper and out-of-round.
Replace defective part as necessary
BR/BEENGINE 3.9L 9 - 9
ENGINE 3.9L (Continued)

material is for use between two machined surfaces.
Do not use on flexible metal flanges.
MOPARtGASKET SEALANT
MopartGasket Sealant is a slow drying, perma-
nently soft sealer. This material is recommended for
sealing threaded fittings and gaskets against leakage
of oil and coolant. Can be used on threaded and
machined parts under all temperatures. This mate-
rial is used on engines with multi-layer steel (MLS)
cylinder head gaskets. This material also will pre-
vent corrosion. MopartGasket Sealant is available in
a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assembling parts using a form-in-place gasket
requires care but it's easier then using precut gas-
kets.
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
MopartGasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the upper crossmember and top core
support.
(4) Remove the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
REMOVAL).(5) Discharge the air conditioning system, if
equipped (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove the A/C compressor with the lines
attached. Set aside.
(8) If equipped, remove the condenser (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - REMOVAL).
(9) Remove the washer bottle.
(10) Remove the fan and fan shroud (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(11) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(12) Remove the generator with the wire connec-
tions (Refer to 8 - ELECTRICAL/CHARGING/GEN-
ERATOR - REMOVAL).
(13) Remove the air cleaner box.
(14) Disconnect the throttle linkage.
(15) Remove throttle body (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/THROTTLE BODY -
REMOVAL).
(16) Remove the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL).
(17) Remove the distributor cap and wiring.
(18) Disconnect the heater hoses.
(19) Disconnect the power steering hoses, if
equipped.
(20) Perform the Fuel System Pressure release
procedure (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY - STANDARD PROCEDURE).Disconnect
the fuel supply line (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/QUICK CONNECT FITTING -
STANDARD PROCEDURE).
(21) On Manual Transmission vehicles, remove the
shift lever.
(22) Raise and support the vehicle on a hoist.
(23) Remove the drain plug and drain the engine
oil.
(24) Remove engine front mount through-bolt nuts.
(25)Automatic TransmissionRemove the trans-
mission cooler line brackets from oil pan.
(26) Disconnect exhaust pipe at manifold.
(27) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).
(28)Manual TransmissionRemove the transmis-
sion.(Refer to 21 - TRANSMISSION/TRANSAXLE/
MANUAL - REMOVAL).
(29) Lower the vehicle.
CAUTION: DO NOT lift the engine by the intake
manifold.
(30) Install an engine lifting fixture.
9 - 12 ENGINE 3.9LBR/BE
ENGINE 3.9L (Continued)