fuel filter DODGE RAM 2001 Service Owner's Manual

FRONT MOUNT
REMOVAL.............................100
INSTALLATION..........................100
REAR MOUNT
REMOVAL.............................101
INSTALLATION..........................101
LUBRICATION
DESCRIPTION..........................102
OPERATION............................102
DIAGNOSIS AND TESTING................104
ENGINE OIL LEAKS....................104
ENGINE OIL PRESSURE................104
OIL
STANDARD PROCEDURE.................104
ENGINE OIL..........................104
OIL FILTER
REMOVAL.............................105
INSTALLATION..........................105
OIL PAN
REMOVAL.............................105
CLEANING.............................106
INSPECTION...........................106
INSTALLATION..........................106
OIL PUMP
REMOVAL.............................107
DISASSEMBLY..........................107INSPECTION...........................107
ASSEMBLY............................109
INSTALLATION..........................109
INTAKE MANIFOLD
DESCRIPTION..........................109
OPERATION............................109
DIAGNOSIS AND TESTING................110
INTAKE MANIFOLD LEAKAGE............110
REMOVAL.............................110
CLEANING.............................110
INSPECTION...........................110
INSTALLATION..........................111
EXHAUST MANIFOLD
DESCRIPTION..........................112
OPERATION............................112
REMOVAL.............................112
CLEANING.............................112
INSPECTION...........................112
INSTALLATION..........................113
TIMING BELT / CHAIN COVER(S)
REMOVAL.............................113
INSTALLATION..........................113
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL.............................114
INSPECTION...........................114
INSTALLATION..........................115
ENGINE 5.2L
DESCRIPTION
The 5.2 Liter (318 CID) eight-cylinder engine is a
V-Type lightweight, single cam, overhead valve
engine with hydraulic roller tappets. This engine is
designed for unleaded fuel.
Engine lubrication system consists of a rotor type
oil pump and a full flow oil filter.The cylinders are numbered from front to rear; 1,
3, 5, 7 on the left bank and 2, 4, 6, 8 on the right
bank. The firing order is 1-8-4-3-6-5-7-2 (Fig. 1).
The engine serial number is stamped into a
machined pad located on the left, front corner of the
cylinder block. When component part replacement is
necessary, use the engine type and serial number for
reference (Fig. 2).
Fig. 1 Firing Order
Fig. 2 Engine Identification (Serial) Number
9 - 60 ENGINE 5.2LBR/BE

CONDITION POSSIBLE CAUSES CORRECTION
3. Worn or incorrect gapped spark
plugs3. Clean plugs and set gap. (Refer to 8
- ELECTRICAL/IGNITION CONTROL/
SPARK PLUG - CLEANING).
4. Dirt or water in fuel system 4. Clean system and replace fuel filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression 8. Test cylinder compression (Refer to
9 - ENGINE - DIAGNOSIS AND
TESTING).
9. Burned, warped, or pitted valves 9. Install/Reface valves as necessary
10. Plugged or restricted exhaust
system10. Install new parts as necessary
11. Faulty ignition cables 11. Replace any cracked or shorted
cables
12. Faulty ignition coil 12. Test and replace, as necessary
(Refer to 8 - ELECTRICAL/IGNITION
CONTROL/IGNITION COIL -
REMOVAL).
ENGINE STALLS OR
ROUGH IDLE1. Carbon build-up on throttle plate 1. Remove throttle body and de-
carbon. (Refer to 14 - FUEL SYSTEM/
FUEL INJECTION/THROTTLE BODY -
REMOVAL).
2. Engine idle speed too low 2. Check Idle Air Control circuit. (Refer
to 14 - FUEL SYSTEM/FUEL
INJECTION/IDLE AIR CONTROL
MOTOR - DESCRIPTION)
3. Worn or incorrectly gapped spark
plugs3. Replace or clean and re-gap spark
plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG -
CLEANING)
4. Worn or burned distributor rotor 4. Install new distributor rotor
5. Spark plug cables defective or
crossed5. Check for correct firing order or
replace spark plug cables. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL/
SPARK PLUG CABLE - DIAGNOSIS
AND TESTING)
6. Faulty coil 6. Test and replace, if necessary (Refer
to 8 - ELECTRICAL/IGNITION
CONTROL/IGNITION COIL -
REMOVAL)
7. Intake manifold vacuum leak 7. Inspect intake manifold gasket and
vacuum hoses (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD -
DIAGNOSIS AND TESTING).
9 - 62 ENGINE 5.2LBR/BE
ENGINE 5.2L (Continued)

(1) Perform the Fuel Pressure Release Procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(2) Disconnect the negative cable(s) from the bat-
tery.
(3) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(4) Place a shop towel around the spark plugs to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the spark plugs.
(5) With all spark plugs removed, rotate the crank-
shaft using a breaker bar and socket.
(6) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
(7) Be sure all fluid has been removed from the
cylinders.
(8) Repair engine or components as necessary to
prevent this problem from occurring again.
(9) Squirt a small amount of engine oil into the
cylinders to lubricate the walls. This will prevent
damage on restart.
(10) Install new spark plugs. Tighten the spark
plugs to 41 N´m (30 ft. lbs.) torque.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N´m (25 ft. lbs.) torque.
(13) Install a new oil filter.
(14) Fill engine crankcase with the specified
amount and grade of oil. (Refer to LUBRICATION &
MAINTENANCE - SPECIFICATIONS).
(15) Connect the negative cable(s) to the battery.
(16) Start the engine and check for any leaks.
STANDARD PROCEDUREÐCYLINDER BORE
HONING
Before honing, stuff plenty of clean shop towels
under the bores and over the crankshaft to keep
abrasive materials from entering the crankshaft
area.
(1) Used carefully, the Cylinder Bore Sizing Hone
C-823, equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round, as well as removing light
scuffing, scoring and scratches. Usually, a few strokes
will clean up a bore and maintain the required lim-
its.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done if
the cylinder bore is straight and round. Use a cylin-
der surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). about 20-60strokes, depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Using honing
oil C-3501-3880, or a light honing oil, available from
major oil distributors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.
(3) Honing should be done by moving the hone up
and down fast enough to get a crosshatch pattern.
The hone marks should INTERSECT at 50É to 60É
for proper seating of rings (Fig. 3).
(4) A controlled hone motor speed between 200 and
300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 50É to 60É
angle. Faster up and down strokes increase the cross-
hatch angle.
(5) After honing, it is necessary that the block be
cleaned to remove all traces of abrasive. Use a brush
to wash parts with a solution of hot water and deter-
gent. Dry parts thoroughly. Use a clean, white, lint-
free cloth to check that the bore is clean. Oil the
bores after cleaning to prevent rusting.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Recover refrigerant from a/c system, if
equipped (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(4) Remove the a/c condenser, if equipped (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - REMOVAL).
Fig. 3 Cylinder Bore Crosshatch Pattern
1 - CROSSHATCH PATTERN
2 - INTERSECT ANGLE
BR/BEENGINE 5.2L 9 - 69
ENGINE 5.2L (Continued)

FRONT MOUNT
REMOVAL.............................156
INSTALLATION..........................156
REAR MOUNT
REMOVAL.............................157
INSTALLATION..........................158
LUBRICATION
DESCRIPTION..........................158
OPERATION............................158
DIAGNOSIS AND TESTING................160
ENGINE OIL LEAKS....................160
ENGINE OIL PRESSURE................160
OIL
STANDARD PROCEDURE.................160
ENGINE OIL..........................160
OIL FILTER
REMOVAL.............................161
INSTALLATION..........................161
OIL PAN
REMOVAL.............................161
CLEANING.............................162
INSPECTION...........................162
INSTALLATION..........................162
OIL PUMP
REMOVAL.............................162
DISASSEMBLY..........................163INSPECTION...........................163
ASSEMBLY............................165
INSTALLATION..........................165
INTAKE MANIFOLD
DESCRIPTION..........................165
OPERATION............................165
DIAGNOSIS AND TESTING................165
INTAKE MANIFOLD LEAKAGE............165
REMOVAL.............................166
CLEANING.............................166
INSPECTION...........................166
INSTALLATION..........................166
EXHAUST MANIFOLD
DESCRIPTION..........................168
OPERATION............................168
REMOVAL.............................168
CLEANING.............................168
INSPECTION...........................168
INSTALLATION..........................168
TIMING BELT / CHAIN COVER(S)
REMOVAL.............................169
INSTALLATION..........................169
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL.............................170
INSPECTION...........................170
INSTALLATION..........................170
ENGINE 5.9L
DESCRIPTION
The 5.9 Liter (360 CID) eight-cylinder engine is a
V-Type lightweight, single cam, overhead valve
engine with hydraulic roller tappets. This engine is
designed for unleaded fuel.
The engine lubrication system consists of a rotor
type oil pump and a full flow oil filter.
The cylinders are numbered from front to rear; 1,
3, 5, 7 on the left bank and 2, 4, 6, 8 on the right
bank. The firing order is 1-8-4-3-6-5-7-2 (Fig. 1).The engine serial number is stamped into a
machined pad located on the left, front corner of the
cylinder block. When component part replacement is
necessary, use the engine type and serial number for
reference (Fig. 2).
Fig. 1 Firing Order
Fig. 2 Engine Identification Number
BR/BEENGINE 5.9L 9 - 117

CONDITION POSSIBLE CAUSES CORRECTION
ENGINE LOSS OF POWER 1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn distributor shaft 2. Remove and repair distributor
(Refer to 8 - ELECTRICAL/
IGNITION CONTROL/
DISTRIBUTOR - REMOVAL).
3. Worn or incorrect gapped spark
plugs3. Clean plugs and set gap. (Refer
to 8 - ELECTRICAL/IGNITION
CONTROL/SPARK PLUG -
CLEANING).
4. Dirt or water in fuel system 4. Clean system and replace fuel
filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression 8. Test cylinder compression (Refer
to 9 - ENGINE - DIAGNOSIS AND
TESTING).
9. Burned, warped, or pitted valves 9. Install/Reface valves as
necessary
10. Plugged or restricted exhaust
system10. Install new parts as necessary
11. Faulty ignition cables 11. Replace any cracked or shorted
cables
12. Faulty ignition coil 12. Test and replace, as necessary
(Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL).
ENGINE STALLS OR ROUGH IDLE 1. Carbon build-up on throttle plate 1. Remove throttle body and
de-carbon. (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/
THROTTLE BODY - REMOVAL).
2. Engine idle speed too low 2. Check Idle Air Control circuit.
(Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/IDLE AIR CONTROL
MOTOR - DESCRIPTION)
3. Worn or incorrectly gapped spark
plugs3. Replace or clean and re-gap
spark plugs (Refer to 8 -
ELECTRICAL/IGNITION CONTROL/
SPARK PLUG - CLEANING)
4. Worn or burned distributor rotor 4. Install new distributor rotor
5. Spark plug cables defective or
crossed5. Check for correct firing order or
replace spark plug cables. (Refer to
8 - ELECTRICAL/IGNITION
CONTROL/SPARK PLUG CABLE -
DIAGNOSIS AND TESTING)
6. Faulty coil 6. Test and replace, if necessary
(Refer to 8 - ELECTRICAL/
IGNITION CONTROL/IGNITION
COIL - REMOVAL)
BR/BEENGINE 5.9L 9 - 119
ENGINE 5.9L (Continued)

(1) Perform the Fuel Pressure Release Procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(2) Disconnect the negative cable(s) from the bat-
tery.
(3) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(4) Place a shop towel around the spark plugs to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the spark plugs.
(5) With all spark plugs removed, rotate the crank-
shaft using a breaker bar and socket.
(6) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
(7) Be sure all fluid has been removed from the
cylinders.
(8) Repair engine or components as necessary to
prevent this problem from occurring again.
(9) Squirt a small amount of engine oil into the
cylinders to lubricate the walls. This will prevent
damage on restart.
(10) Install new spark plugs. Tighten the spark
plugs to 41 N´m (30 ft. lbs.) torque.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N´m (25 ft. lbs.) torque.
(13) Install a new oil filter.
(14) Fill engine crankcase with the specified
amount and grade of oil. (Refer to LUBRICATION &
MAINTENANCE - SPECIFICATIONS).
(15) Connect the negative cable(s) to the battery.
(16) Start the engine and check for any leaks.
STANDARD PROCEDUREÐCYLINDER BORE
HONING
Before honing, stuff plenty of clean shop towels
under the bores and over the crankshaft to keep
abrasive materials from entering the crankshaft
area.
(1) Used carefully, the Cylinder Bore Sizing Hone
C-823, equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round, as well as removing light
scuffing, scoring and scratches. Usually, a few strokes
will clean up a bore and maintain the required lim-
its.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done if
the cylinder bore is straight and round. Use a cylin-
der surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). about 20-60strokes, depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Using honing
oil C-3501-3880, or a light honing oil, available from
major oil distributors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.
(3) Honing should be done by moving the hone up
and down fast enough to get a crosshatch pattern.
The hone marks should INTERSECT at 40É to 60É
for proper seating of rings (Fig. 3).
(4) A controlled hone motor speed between 200 and
300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 40É to 60É
angle. Faster up and down strokes increase the cross-
hatch angle.
(5) After honing, it is necessary that the block be
cleaned to remove all traces of abrasive. Use a brush
to wash parts with a solution of hot water and deter-
gent. Dry parts thoroughly. Use a clean, white, lint-
free cloth to check that the bore is clean. Oil the
bores after cleaning to prevent rusting.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Recover refrigerant from a/c system, if
equipped (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(4) Remove the a/c condenser, if equipped (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - REMOVAL).
Fig. 3 Cylinder Bore Crosshatch Pattern
1 - CROSSHATCH PATTERN
2 - INTERSECT ANGLE
9 - 126 ENGINE 5.9LBR/BE
ENGINE 5.9L (Continued)

LUBRICATION
DESCRIPTION..........................214
OPERATION............................214
DIAGNOSIS AND TESTING................215
ENGINE OIL LEAKS....................215
ENGINE OIL PRESSURE................215
OIL
STANDARD PROCEDURE.................217
ENGINE OIL..........................217
OIL FILTER
REMOVAL.............................218
INSTALLATION..........................218
OIL PAN
REMOVAL.............................218
CLEANING.............................218
INSPECTION...........................219
INSTALLATION..........................219
OIL PUMP
REMOVAL.............................219
CLEANING.............................220
INSPECTION...........................220
INSTALLATION..........................221INTAKE MANIFOLD
DESCRIPTION..........................222
DIAGNOSIS AND TESTING................222
INTAKE MANIFOLD LEAKAGE............222
REMOVAL.............................222
CLEANING.............................223
INSPECTION...........................223
INSTALLATION..........................223
EXHAUST MANIFOLD
DESCRIPTION..........................224
OPERATION............................224
REMOVAL.............................225
CLEANING.............................225
INSPECTION...........................225
INSTALLATION..........................225
TIMING BELT / CHAIN COVER(S)
REMOVAL.............................225
INSTALLATION..........................226
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL.............................226
INSPECTION...........................227
INSTALLATION..........................227
ENGINE 8.0L
DESCRIPTION
The 8.0 Liter (488 CID) ten-cylinder engine is a
V-Type lightweight, single cam, overhead valveengine with hydraulic roller tappets. This engine is
designed for unleaded fuel.
Engine lubrication system consists of a gerotor type
oil pump mounted in the timing chain cover and driven
by the crankshaft. The V-10 uses a full flow oil filter.
The cylinders are numbered from front to rear; 1, 3,
5, 7, 9 on the left bank and 2, 4, 6, 8, 10 on the right
bank. The firing order is 1-10-9-4-3-6-5-8-7-2 (Fig. 1).
The engine serial number is located on the lower
left front of the cylinder block in front of the engine
mount (Fig. 2). When component part replacement is
necessary, use the engine type and serial number for
reference.
Fig. 1 Firing Order
Fig. 2 Engine IdentificationÐ(Serial Number)
1 - ENGINE SERIAL NO.
2 - ENGINE MOUNT LOCATION
9 - 172 ENGINE 8.0LBR/BE

CONDITION POSSIBLE CAUSES CORRECTION
ENGINE LOSS OF POWER 1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn distributor shaft 2. Remove and repair distributor
(Refer to 8 - ELECTRICAL/IGNITION
CONTROL/DISTRIBUTOR -
REMOVAL).
3. Worn or incorrect gapped spark
plugs3. Clean plugs and set gap. (Refer to
8 - ELECTRICAL/IGNITION
CONTROL/SPARK PLUG -
CLEANING).
4. Dirt or water in fuel system 4. Clean system and replace fuel filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression 8. Test cylinder compression (Refer to
9 - ENGINE - DIAGNOSIS AND
TESTING).
9. Burned, warped, or pitted valves 9. Install/Reface valves as necessary
10. Plugged or restricted exhaust
system10. Install new parts as necessary
11. Faulty ignition cables 11. Replace any cracked or shorted
cables
12. Faulty ignition coil 12. Test and replace, as necessary
(Refer to 8 - ELECTRICAL/IGNITION
CONTROL/IGNITION COIL -
REMOVAL).
ENGINE STALLS OR ROUGH IDLE 1. Carbon build-up on throttle plate 1. Remove throttle body and
de-carbon. (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/
THROTTLE BODY - REMOVAL).
2. Engine idle speed too low 2. Check Idle Air Control circuit.
(Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/IDLE AIR CONTROL
MOTOR - DESCRIPTION)
3. Worn or incorrectly gapped spark
plugs3. Replace or clean and re-gap spark
plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG -
CLEANING)
4. Worn or burned distributor rotor 4. Install new distributor rotor
5. Spark plug cables defective or
crossed5. Check for correct firing order or
replace spark plug cables. (Refer to 8
- ELECTRICAL/IGNITION CONTROL/
SPARK PLUG CABLE - DIAGNOSIS
AND TESTING)
6. Faulty coil 6. Test and replace, if necessary
(Refer to 8 - ELECTRICAL/IGNITION
CONTROL/IGNITION COIL -
REMOVAL)
9 - 174 ENGINE 8.0LBR/BE
ENGINE 8.0L (Continued)

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.
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) Perform the Fuel Pressure Release Procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(2) Disconnect the negative cable(s) from the bat-
tery.
(3) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(4) Place a shop towel around the spark plugs to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the spark plugs.
(5) With all spark plugs removed, rotate the crank-
shaft using a breaker bar and socket.
(6) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
(7) Be sure all fluid has been removed from the
cylinders.
(8) Repair engine or components as necessary to
prevent this problem from occurring again.
(9) Squirt a small amount of engine oil into the
cylinders to lubricate the walls. This will prevent
damage on restart.
(10) Install new spark plugs. Tighten the spark
plugs to 41 N´m (30 ft. lbs.) torque.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N´m (25 ft. lbs.) torque.
(13) Install a new oil filter.
(14) Fill engine crankcase with the specified
amount and grade of oil. (Refer to LUBRICATION &
MAINTENANCE - SPECIFICATIONS).
(15) Connect the negative cable(s) to the battery.
(16) Start the engine and check for any leaks.
REMOVAL
(1) Remove the battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Discharge the air conditioning system, if
equipped (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(4) Remove the upper crossmember.
(5) Remove the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
REMOVAL).
BR/BEENGINE 8.0L 9 - 181
ENGINE 8.0L (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)