Heat DODGE RAM 2001 Service Repair Manual

FRONT MOUNT
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Position fan to assure clearance for radiator top
tank and hose.
CAUTION: DO NOT lift the engine by the intake
manifold.
(3) Install engine support/lifting fixture.
(4) Raise vehicle on hoist.
(5) Lift the engine SLIGHTLY and remove the
thru-bolt and nut (Fig. 48).
(6) Remove engine support bracket/cushion bolts
(Fig. 48). Remove the support bracket/cushion and
heat shields.
INSTALLATION
(1) With engine raised SLIGHTLY, position the
engine support bracket/cushion and heat shields to
the block. Install new bolts and tighten to 81 N´m (60
ft. lbs.) torque.
(2) Install the thru-bolt and 2 piece rubber engine
rubber restrictors onto the engine support bracket/
cushion.
(3) Lower engine with support/lifting fixture while
guiding the engine bracket/cushion and thru-bolt into
support cushion brackets (Fig. 49).
(4) Install thru-bolt nuts and tighten the nuts to
68 N´m (50 ft. lbs.) torque.
(5) Lower the vehicle.
(6) Remove lifting fixture.
REAR MOUNT
REMOVAL
(1) Raise the vehicle on a hoist.
(2) Position a transmission jack in place.
(3) Remove support cushion stud nuts (Fig. 50).
(4) Raise rear of transmission and engine
SLIGHTLY.
(5) Remove the bolts holding the support cushion
to the transmission support bracket. Remove the sup-
port cushion.
(6) If necessary, remove the bolts holding the
transmission support bracket to the transmission.
INSTALLATION
(1) If removed, position the transmission support
bracket to the transmission. Install new attaching
bolts and tighten to 102 N´m (75 ft. lbs.) torque.
(2) Position support cushion to transmission sup-
port bracket. Install stud nuts and tighten to 47 N´m
(35 ft. lbs.) torque.
(3) Using the transmission jack, lower the trans-
mission and support cushion onto the crossmember
(Fig. 50).
(4) Install the support cushion bolts and tighten to
47 N´m (35 ft. lbs.) torque.
(5) Remove the transmission jack.
(6) Lower the vehicle.
Fig. 48 Engine Front Mounts
1 - ENGINE MOUNT HEAT SHIELD
2 - THRU-BOLT
3 - RESTRICTION PADS
4 - ENGINE SUPPORT BRACKET/CUSHION
Fig. 49 Positioning Engine MountsÐFront
1 - ENGINE SUPPORT BRACKET/CUSHION
2 - SUPPORT CUSHION BRACKET
BR/BEENGINE 8.0L 9 - 213

(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)

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 (Fig. 76).
(6) Remove the dipstick bracket from the exhaust
manifold (right side only).(7) Remove bolts attaching manifold to cylinder
head.
(8) Remove manifold from the cylinder head. Dis-
card the gasket.
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
(1) Using a new gasket position the engine
exhaust manifold onto the cylinder head. Install bolts
and stud bolts in the proper position. (Fig. 76)
Tighten the bolts to 22 N´m (16 ft. lbs.) torque.
(2) Install the dipstick bracket on to the exhaust
manifold (right side only).
(3) Position washers and exhaust heat shields onto
the manifold stud bolts (Fig. 76). Be sure the tabs on
the heat shields are hooked over the top of the
exhaust gasket. Install the nuts and tighten to 20
N´m (175 in. lbs.) torque.
(4) Raise and support the vehicle.
(5) Assemble exhaust pipe to manifold.
(6) Lower the vehicle.
(7) Connect the negative cable to the battery.
(8) Start engine check for leaks.
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - REMOV-
AL).
(4) Remove fan and fan shroud (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(5) Unbolt A/C compressor and set on top of
engine.
(6) Remove generator, air pump, and bracket
assembly.
(7) Remove water pump (Refer to 7 - COOLING/
ENGINE/WATER PUMP - REMOVAL).
(8) Remove damper bolt and washer.
(9) Using Special Tool 1026 3-Jaw Puller remove
pulley/damper from the crankshaft. (Fig. 77)
Fig. 75 Exhaust ManifoldÐ8.0L Engine
1 - EXHAUST MANIFOLD
Fig. 76 8.0L Engine Exhaust ManifoldÐTypical
1 - EXHAUST MANIFOLD
2 - HEAT SHIELD
BR/BEENGINE 8.0L 9 - 225
EXHAUST MANIFOLD (Continued)

(10) Loosen oil pan bolts and remove the front oil
pan bolts that mount the pan to the timing chain
cover.
(11) Remove the cover bolts.
(12) Remove timing chain cover and gasket using
extreme caution to avoid damaging oil pan gasket.
(13) Inspect surface of cover. Remove any burrs or
high spots.
INSTALLATION
(1) Be sure mating surfaces of timing chain cover
and cylinder block are clean and free from burrs.
(2) Lubricate the pump rotors using petroleum
jelly or lubriplate (Refer to 9 - ENGINE/LUBRICA-
TION/OIL PUMP - INSTALLATION).
(3) Using a new cover gasket, carefully install tim-
ing chain cover to avoid damaging oil pan gasket.
Use a small amount of MopartSilicone Rubber Adhe-
sive Sealant, or equivalent, at the joint between tim-
ing chain cover gasket and the oil pan gasket. Finger
tighten the timing chain cover bolts at this time.
(4) Tighten timing chain cover bolts to 47 N´m (35
ft. lbs.) torque. Tighten oil pan bolts to 24 N´m (215
in. lbs.) torque.
(5) Using Special Tool C-3688 Crankshaft Pulley/
Damper Installer Install pulley/vibration damper
(Fig. 78)
(6) Prime oil pump by squirting oil in the oil filter
mounting hole and filling the J-trap of the front tim-
ing cover. When oil is running out, install oil filter
that has been filled with oil.(7) Install water pump and housing assembly
using new o-ring (Refer to 7 - COOLING/ENGINE/
WATER PUMP - INSTALLATION).
(8) Install generator, air pump, and bracket assem-
bly.
(9) Install A/C compressor (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/A/C COM-
PRESSOR - INSTALLATION).
(10) (10) Install the radiator fan (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
(11) Position the fan shroud and install the bolts.
Tighten the bolts to 11 N´m (95 in. lbs.) torque.
(12) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(13) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(14) Connect the negative cable to the battery.
(15) Road test vehicle and check for leaks.
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
(1) Remove timing chain cover and gasket using
extreme caution to avoid damaging oil pan gasket
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - REMOVAL).
Fig. 77 PulleyÐDamper Removal
1-3JAWPULLER
Fig. 78 Installing Crankshaft
1 - SPECIAL TOOL C-3688
9 - 226 ENGINE 8.0LBR/BE
TIMING BELT / CHAIN COVER(S) (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)

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.
STANDARD PROCEDUREÐREPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repaired. Essen-
tially, this repair consists of:
²Drilling out worn or damaged threads.
²Tapping the hole with a special Heli-Coil Tap, or
equivalent.
²Installing an insert into the tapped hole to bring
the hole back to its original thread size.
STANDARD PROCEDUREÐHYDROSTATIC
LOCK
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.When an engine is suspected of hydrostatic lock
(regardless of what caused the problem), follow the
steps below.
(1) Disconnect the negative cable(s) from the bat-
tery.
(2) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(3) Place a shop towel around the fuel injectors to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the fuel injectors (Refer
to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL
INJECTOR - REMOVAL).
(4) With all injectors removed, rotate the crank-
shaft using a breaker bar and socket.
(5) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
(6) Be sure all fluid has been removed from the
cylinders.
(7) Repair engine or components as necessary to
prevent this problem from occurring again.
(8) Squirt a small amount of engine oil into the
cylinders to lubricate the walls. This will prevent
damage on restart.
(9) Install new fuel injectors (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/FUEL INJECTOR -
INSTALLATION).
(10) Drain engine oil. Remove and discard the oil
filter (Refer to 9 - ENGINE/LUBRICATION/OIL FIL-
TER - REMOVAL).
(11) Install the drain plug. Tighten the plug to 34
N´m (25 ft. lbs.) torque.
(12) Install a new oil filter (Refer to 9 - ENGINE/
LUBRICATION/OIL FILTER - INSTALLATION).
(13) Fill engine crankcase with the specified
amount and grade of oil (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES - SPECIFICA-
TIONS).
(14) Connect the negative cable(s) to the battery.
(15) Start the engine and check for any leaks.
REMOVALÐENGINE
(1) Disconnect both battery negative cables.
(2) Recover A/C refrigerant (if A/C equipped) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE).
(3) Raise vehicle on hoist.
(4) Drain engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(5) Remove engine oil drain plug and drain engine
oil.
(6) Lower vehicle.
(7) Remove radiator upper hose.
(8) Remove the cooling fan shroud-to-radiator
mounting bolts.
9 - 238 ENGINE 5.9L DIESELBR/BE
ENGINE 5.9L DIESEL (Continued)

(9) Remove viscous fan/drive assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
Remove the cooling fan and shroud together.
(10) Disconnect the coolant recovery bottle hose
from the radiator filler neck and remove bottle from
fan shroud (Fig. 2).
(11) Disconnect heater core supply and return
hoses from the cylinder head fitting and coolant pipe.
(12) Raise vehicle on hoist.
(13) Remove transmission and transfer case (if
equipped.).
(14) Disconnect exhaust pipe from turbocharger
extension pipe (Fig. 3).
(15) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).
(16) Disconnect A/C suction/discharge hose from
the rear of the A/C compressor.
(17) Lower vehicle.
(18) Disconnect lower radiator hose from radiator
outlet.
(19)Automatic Transmission models:Discon-
nect transmission oil cooler lines from radiator using
special tool #6931.
(20) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(21) Remove upper radiator support panel.
(22)
Remove front bumper (Refer to 13 - FRAMES &
BUMPERS/BUMPERS/FRONT BUMPER - REMOVAL).
(23) If A/C equipped, disconnect A/C condenser
refrigerant lines.
(24) Disconnect charge air cooler piping.
(25) Remove the two charge air cooler mounting
bolts.
(26) Remove charge air cooler (and A/C condenser
if equipped) from vehicle.
(27) Disconnect engine block heater connector.
(28) Disconnect A/C compressor electrical connec-
tors.
(29) Remove the passenger battery ground cable
from the engine block.
(30) Disconnect power steering pump pressure and
return lines.
(31) Remove accelerator linkage cover.
(32) Leaving all cables attached, remove accelera-
tor pedal position sensor assy. (APPS) (Fig. 4) from
cylinder head bracket and secure out of the way.
(33) Disconnect APPS connector (Fig. 5).
(34) Disconnect vacuum pump supply hose (Fig. 6).
(35) Disconnect the engine harness and ground
cable from the PDC.
(36) Disconnect the fuel supply and return hoses
(Fig. 7).
(37) Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(38) Remove the #5 and #6 cylinder intake and
exhaust rocker arms and pedestals (Fig. 8). Note the
original location for re-assembly.
(39) Loosen but do not remove engine mount
through bolts and nuts.
(40) Attach chain accross engine lift brackets.
(41)
Lift engine up and out of engine compartment.
(42) Install engine to suitable engine stand.
Fig. 2 Coolant Recovery Bottle
1 - T-SLOTS
2 - ALIGNMENT PIN
3 - FAN SHROUD
4 - COOLANT RESERVE/OVERFLOW TANK
Fig. 3 Exhaust Pipe Connection at Turbocharger
1 - EXHAUST PIPE
2 - TURBOCHARGER EXHAUST PIPE
BR/BEENGINE 5.9L DIESEL 9 - 239
ENGINE 5.9L DIESEL (Continued)

REMOVALÐCRANKCASE BREATHER VAPOR
CANISTER
NOTE: It is recommended to empty the contents of
the vapor canister at each oil and filter service
interval.
(1) Loosen cap from top of vapor canister.
(2) Remove nut retaining canister to engine front
cover.
(3) Slide clamp upwards on hose, then remove
hose from crankcase breather.
INSTALLATIONÐENGINE
(1) Install the engine with the cylinder head cover
and the #5 and 6 rocker arm assemblies removed.
(2) Lower the engine into the compartment and
install the engine mount through bolts and nuts.
(3) Tighten the mount through bolts and nuts to
88 N´m (65 ft. lbs.) torque.
(4) Remove the engine lifting device.
(5) Install the #5 and #6 rocker arms and pedes-
tals in their original locations (Fig. 8). Torque the
mounting bolts to 36 N´m (27 ft. lbs.) torque.
(6) Install the cylinder head cover and gasket
(Refer to 9 - ENGINE/CYLINDER HEAD - INSTAL-
LATION).
(7) Connect the fuel supply and return hoses (Fig.
7).
(8) Connect the engine harness connector and
ground cable to the PDC.
(9) Connect the vacuum pump supply hose.(10) Connect the APPS connector (Fig. 5).
(11) Install the APPS assembly bracket to the cyl-
inder head bracket.
(12) Install the throttle linkage cover.
(13) Connect the power steering pressure and
return lines.
(14) Connect the passenger battery ground cable to
the engine block. Tighten the bolt to 77 N´m (57 ft.
lbs.) torque.
(15) Connect the engine block heater connector.
(16) Connect the a/c compressor electrical connec-
tors.
(17) Install the charge air cooler and a/c condenser
(if a/c equipped). Install and tighten the charge air
cooler mounting bolts to 2 N´m (17 in. lbs.) torque.
(18) Connect the charge air cooler piping. Torque
all clamps to 8 N´m (72 in. lbs.) torque.
(19) Connect the a/c refrigerant lines to the a/c
condenser (if equipped).
(20) Install the front bumper (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT
BUMPER - INSTALLATION).
(21) Install the radiator upper support panel.
(22) Install the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION).
Fig. 8 Rocker Arm and PedestalÐRemoval/
Installation
1 - ROCKER ARM
2 - PEDESTALFig. 9 Crankcase Breather Vapor Canister
1 - ENGINE FRONT COVER STUD
2 - STRAP
3 - VAPOR CANISTER
4 - NUT
5 - CAP
6 - CRANKCASE BREATHER
7 - CLAMP
8 - HOSE
BR/BEENGINE 5.9L DIESEL 9 - 241
ENGINE 5.9L DIESEL (Continued)