battery DODGE RAM 2001 Service Repair Manual

(5) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION) and throttle body assembly.
(6) Install exhaust manifolds (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
INSTALLATION).
(7) Adjust spark plugs to specifications. Install the
plugs and tighten to 41 N´m (30 ft. lbs.) torque.
(8) Install coil wires.
(9) Connect coolant temperature sending unit wire.
(10) Connect the fuel injector harness.
(11) Connect the vacuum supply hoses to the
intake manifold.
(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.
(16) Install the generator and accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE
BELTS - INSTALLATION). Tighten generator
mounting bolt to 41 N´m (30 ft. lbs.) torque.
(17) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts.
(18) 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 resonator assembly, air in-let hose
and air cleaner.
(22) Install the heat shields. Tighten the bolts to
41 N´m (30 ft. lbs.) torque.
(23) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(24) Connect the battery negative cable.
CYLINDER HEAD COVER(S)
REMOVAL
A steel-backed silicone gasket is used with the cyl-
inder head cover (Fig. 8). This gasket can be used
again.
(1) Disconnect the negative cable from the battery.
(2) Disconnect closed ventilation system and evap-
oration control system from cylinder head cover.
(3) Remove cylinder head cover bolts, cover and
gasket. The gasket may be used again.
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
A steel-backed silicone gasket is used with the cyl-
inder head cover (Fig. 8). This gasket can be used
again.
(1) Position the cylinder head cover gasket onto
the head rail.
(2) Position the cylinder head cover onto the gas-
ket and install the bolts. Tighten the bolts to 11 N´m
(95 in. lbs.) torque.
(3) Install closed crankcase ventilation system and
evaporation control system.
(4) Connect the negative cable to the battery.
(5) Start engine and check for leaks.
Fig. 7 Cylinder Head Bolt -Tightening Sequence
Fig. 8 Cylinder Head Cover Gasket
1 - CYLINDER HEAD COVER GASKET
9 - 24 ENGINE 3.9LBR/BE
CYLINDER HEAD (Continued)

Bearing Mount Adhesive. Plug should be 54.0 to 57.7
mm (2-1/8 to 2-5/16 in.) from bottom of the block.
CAMSHAFT & BEARINGS (IN
BLOCK)
REMOVALÐCAMSHAFT BEARINGS
(1) With engine completely disassembled, drive out
rear cam bearing core hole plug.
(2) Install proper size adapters and horseshoe
washers (part of Camshaft Bearing Remover/Installer
Tool C-3132-A) at back of each bearing shell. Drive
out bearing shells (Fig. 18).
REMOVALÐCAMSHAFT
(1) Disconnect battery negative cable.
(2) Remove radiator. (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(3) Remove intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL).
(4) Remove distributor assembly. Refer to Ignition
Systems for the correct procedure.
(5) Remove cylinder head covers (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(6) Remove rocker arms.
(7) Remove push rods and tappets (Refer to 9 -
ENGINE/ENGINE BLOCK/HYDRAULIC LIFTERS
(CAM IN BLOCK) - REMOVAL). Identify each part
so it can be installed in the original locations.
(8) Remove timing chain cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(9) Align timing marks (Fig. 19) and remove tim-
ing chain and sprockets.
(10) Remove the three tensioner to block mounting
bolts and remove tensioner.(11) Install a long bolt into front of camshaft to aid
in removal of the camshaft. Remove camshaft, being
careful not to damage cam bearings with the cam
lobes.
INSTALLATIONÐCAMSHAFT BEARINGS
(1) Install new camshaft bearings with Camshaft
Bearing Remover/Installer Tool C-3132-A by sliding
the new camshaft bearing shell over proper adapter.
(2) Position rear bearing in the tool. Install horse-
shoe lock and, by reversing removal procedure, care-
fully drive bearing shell into place.
(3) Install remaining bearings in the same man-
ner. Bearings must be carefully aligned to bring oil
holes into full register with oil passages from the
main bearing. If the camshaft bearing shell oil holes
are not in exact alignment, remove and install them
correctly. Install a new core hole plug at the rear of
camshaft.Be sure this plug does not leak.
INSTALLATIONÐCAMSHAFT
(1) Lubricate camshaft lobes and camshaft bearing
journals and insert the camshaft to within 51 mm (2
inches) of its final position in cylinder block.
(2) Install Camshaft Holding Tool C-3509 with
tongue back of distributor drive gear (Fig. 20).
(3) Hold tool in position with a distributor lock-
plate bolt. This tool will restrict camshaft from being
pushed in too far and prevent knocking out the welch
plug in rear of cylinder block.Tool should remain
Fig. 18 Camshaft Bearings Removal and Installation
with Tool C-3132-A
1 - SPECIAL TOOL C-3132A
Fig. 19 Alignment of Timing Marks
1 - TIMING MARKS
BR/BEENGINE 3.9L 9 - 29
ENGINE BLOCK (Continued)

(8) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam-
shaft sprocket.
(9) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(10) Slide both sprockets evenly over their respec-
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 22).
(11) Install the camshaft bolt/cup washer. Tighten
bolt to 68 N´m (50 ft. lbs.) torque.
(12) Measure camshaft end play (Fig. 23). (Refer to
9 - ENGINE - SPECIFICATIONS) for proper clear-
ance. If not within limits, install a new timing chain
tensioner.
(13) Each tappet reused must be installed in the
same position at which it was removed.When cam-
shaft is replaced, all of the tappets must be
replaced.Install hydraulic tappets (Refer to 9 -
ENGINE/ENGINE BLOCK/HYDRAULIC LIFTERS
(CAM IN BLOCK) - INSTALLATION).
(14) Install timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(15) Install intake manifold (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSTALLA-
TION).
(16) Install distributor.
(17) Install cylinder head covers (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(18) Install radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - INSTALLATION).
(19) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(20) Connect battery negative cable.
(21) Start engine and check for leaks.
CONNECTING ROD BEARINGS
STANDARD PROCEDURE-CONNECTING ROD
BEARING FITTING
Fit all rods on a bank until completed. DO NOT
alternate from one bank to another, because connect-
ing rods and pistons are not interchangeable from
one bank to another.
The bearing caps are not interchangeable and
should be marked at removal to ensure correct
assembly.
Each bearing cap has a small V-groove across the
parting face. When installing the lower bearing shell,
be certain that the V-groove in the shell is in line
with the V-groove in the cap. This provides lubrica-
tion of the cylinder wall in the opposite bank.The bearing shells must be installed so that the
tangs are in the machined grooves in the rods and
caps.
Limits of taper or out-of-round on any crankshaft
journals should be held to 0.025 mm (0.001 in.).
Bearings are available in 0.025 mm (0.001 in.), 0.051
mm (0.002 in.), 0.076 mm (0.003 in.), 0.254 mm
(0.010 in.) and 0.305 mm (0.012 in.) undersize.
Install the bearings in pairs. DO NOT use a new
bearing half with an old bearing half. DO NOT
file the rods or bearing caps.
CRANKSHAFT
DESCRIPTION
The crankshaft (Fig. 24) is of a forged steel splayed
type design, with four main bearing journals.The
crankshaft is located at the bottom of the engine
block and is held in place with four main bearing
caps.
OPERATION
The crankshaft transfers force generated by com-
bustion within the cylinder bores to the flywheel or
flexplate.
REMOVAL
(1) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(2) Remove the oil pump (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - REMOVAL).
(3) Identify bearing caps before removal. Remove
bearing caps and bearings one at a time.
(4) Lift the crankshaft out of the block.
Fig. 24 CrankshaftÐ3.9L Engine
BR/BEENGINE 3.9L 9 - 31
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

INSTALLATION
Only one main bearing should be selectively fitted
while all other main bearing caps are properly tight-
ened. All bearing capbolts removed during service
procedures are to be cleaned and oiled before instal-
lation. DO NOT use a new bearing half with an old
bearing half.
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
(1) Start bearing in place, and insert Crankshaft
Main Bearing Remover/Installer Tool C-3059 into oil
hole of crankshaft (Fig. 29).
(2) Slowly rotate crankshaft counterclockwise slid-
ing the bearing into position. Remove Tool C-3059.
(3) Install the bearing caps. Clean and oil the
bolts. Tighten the capbolts to 115 N´m (85 ft. lbs.)
torque.
(4) Install the oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(5) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
CRANKSHAFT OIL SEAL -
FRONT
DESCRIPTION
The crankshaft rear seal is a two piece viton seal.
The crankshaft front seal is a one piece viton seal
with a steel housing. The front seal is located in the
engine front cover. One part of the two piece rear
seal is located in a slot in the number four (4) crank-
shaft main bore, the second part of the two piece seal
is located in the number four (4) main bearing cap.
OPERATION
The crankshaft seals prevent oil from leaking from
around the crankshaft, either from the rear of the
engine or from the engine front cover.
REMOVAL
The oil seal can be replaced without removing the
timing chain cover, provided that the cover is not
misaligned.
(1) Disconnect the negative cable from the battery.
(2) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(3) If front seal is suspected of leaking, check front
oil seal alignment to crankshaft. The seal installa-
tion/alignment Tool 6635, should fit with minimum
interference. If tool does not fit, the cover must be
removed and installed properly.
(4) Place a suitable tool behind the lips of the oil
seal to pry the oil seal outward. Be careful not to
damage the crankshaft seal bore of cover.
INSTALLATION
(1) Place the smaller diameter of the oil seal over
Front Oil Seal Installation Tool 6635 (Fig. 30). Seat
the oil seal in the groove of the tool.
(2) Position the seal and tool onto the crankshaft
(Fig. 31).
(3) Using the vibration damper bolt, tighten the
bolt to draw the seal into position on the crankshaft
(Fig. 32).
(4) Remove the vibration damper bolt and seal
installation tool.
(5) Inspect the seal flange on the vibration
damper.
(6) Install the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(7) Connect the negative cable to the battery.
CRANKSHAFT OIL SEAL -
REAR
DESCRIPTION
The crankshaft rear seal is a two piece viton seal.
The crankshaft front seal is a one piece viton seal
with a steel housing. The front seal is located in the
engine front cover. One part of the two piece rear
seal is located in a slot in the number four (4) crank-
shaft main bore, the second part of the two piece seal
is located in the number four (4) main bearing cap.
OPERATION
The crankshaft seals prevent oil from leaking from
around the crankshaft, either from the rear of the
engine or from the engine front cover.
Fig. 30 Placing Oil Seal on Installation Tool 6635
1 - CRANKSHAFT FRONT OIL SEAL
2 - INSTALL THIS END INTO SPECIAL TOOL 6635
9 - 34 ENGINE 3.9LBR/BE
CRANKSHAFT MAIN BEARINGS (Continued)

lower rails. Insert oil rail spacer first, then side
rails.
(b) Install the second compression rings using
Installation Tool C-4184. The compression rings
must be installed with the identification mark face
up (toward top of piston) and chamfer facing down.
An identification mark on the ring is a drill point,
a stamped letter ªOº, an oval depression, or the
word ªTOPº (Fig. 41) (Fig. 43).
(c) Using a ring installer, install the top com-
pression ring with the chamfer facing up (Fig. 42)
(Fig. 43). An identification mark on the ring is a
drill point, a stamped letter ªOº, an oval depression
or the word ªTOPº facing up.
(d) Measure side clearance between piston ring
and ring land. Clearance should be 0.074-0.097 mm
(0.0029-0.0038 in.) for the compression rings. The
steel rail oil ring should be free in groove, but
should not exceed 0.246 mm (0.0097 in.) side clear-
ance.
(e) Pistons with insufficient, or excessive, side
clearance should be replaced.
(3) Orient the rings:
(a) Arrange top compression ring 90É counter-
clockwise from the oil ring rail gap (Fig. 44).
(b) Arrange second compression ring 90É clock-
wise from the oil ring rail gap (Fig. 44).
VIBRATION DAMPER
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Remove fan, and fan drive (Refer to 7 - COOL-
ING/ENGINE/FAN DRIVE VISCOUS CLUTCH -
REMOVAL).(3) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(4) Remove the vibration damper pulley.
(5) Remove vibration damper bolt and washer from
end of crankshaft.
(6) Install bar and screw from Puller Tool Set
C-3688. Install two bolts with washers through the
puller tool and into the vibration damper (Fig. 45).
(7) Pull vibration damper off of the crankshaft.
INSTALLATION
(1) Position the vibration damper onto the crank-
shaft.
(2) Place installing tool, part of Puller Tool Set
C-3688, in position and press the vibration damper
onto the crankshaft (Fig. 46).
Fig. 41 Second Compression Ring Identification
(Typical)
1 - SECOND COMPRESSION RING (BLACK CAST IRON)
2 - CHAMFER
3 - TWO DOTS
Fig. 42 Top Compression Ring Identification
(Typical)
1 - TOP COMPRESSION RING (GRAY IN COLOR)
2 - CHAMFER
3 - ONE DOT
Fig. 43 Compression Ring Chamfer Location
(Typical)
1 - CHAMFER
2 - TOP COMPRESSION RING
3 - SECOND COMPRESSION RING
4 - PISTON
5 - CHAMFER
9 - 42 ENGINE 3.9LBR/BE
PISTON RINGS (Continued)

(3) Install the crankshaft bolt and washer. Tighten
the bolt to 244 N´m (180 ft. lbs.) torque.
(4) Install the crankshaft pulley. Tighten the pul-
ley bolts to 23 N´m (200 in. lbs.) torque.(5) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(6) Install viscous fan drive and fan (Refer to 7 -
COOLING/ENGINE/FAN DRIVE VISCOUS
CLUTCH - INSTALLATION).
(7) Install the fan shroud.
(8) Connect the negative cable to the battery.
FRONT MOUNT
REMOVAL
(1) Disconnect the battery negative cable.
(2) Position fan to ensure 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. 47).
(6) Remove engine support bracket/cushion bolts
(Fig. 47). 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 through-bolt into the engine support
bracket/cushion.
Fig. 44 Proper Ring Installation
1 - OIL RING SPACER GAP
2 - SECOND COMPRESSION RING GAP OIL RING RAIL GAP
(TOP)
3 - OIL RING RAIL GAP (BOTTOM)
4 - TOP COMPRESSION RING GAP
Fig. 45 Vibration Damper Assembly
1 - SPECIAL TOOL C-3688
Fig. 46 Installing Vibration Damper
1 - SPECIAL TOOL C-3688
Fig. 47 Engine Front Mounts
1 - ENGINE MOUNT HEAT SHIELD
2 - THRU-BOLT
3 - RESTRICTION PADS
4 - ENGINE SUPPORT BRACKET/CUSHION
BR/BEENGINE 3.9L 9 - 43
VIBRATION DAMPER (Continued)

(6) Add oil only if level is below the ADD mark on
dipstick.
ENGINE OIL CHANGE:
Change engine oil at mileage and time intervals
described in the Maintenance Schedule. This infor-
mation can be found in the owner's manual.
TO CHANGE ENGINE OIL
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Hoist vehicle.
(3) Remove oil fill cap.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket if damaged.
(6) Install drain plug in crankcase.
(7) Change oil filter (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - REMOVAL).
(8) Lower vehicle and fill crankcase with specified
type (Refer to LUBRICATION & MAINTENANCE/
FLUID TYPES - DESCRIPTION) and amount of
engine oil (Refer to LUBRICATION & MAINTE-
NANCE - SPECIFICATIONS).
(9) Install oil fill cap.
(10) Start engine and inspect for leaks.
(11) Stop engine and inspect oil level.
OIL FILTER
REMOVAL
All engines are equipped with a high quality full-
flow, disposable type oil filter. DaimlerChrysler Cor-
poration recommends a Mopartor equivalent oil
filter be used.
(1) Position a drain pan under the oil filter.
(2) Using a suitable oil filter wrench loosen filter.
(3) Rotate the oil filter counterclockwise to remove
it from the cylinder block oil filter boss (Fig. 53).
(4) When filter separates from adapter nipple, tip
gasket end upward to minimize oil spill. Remove fil-
ter from vehicle.
(5) With a wiping cloth, clean the gasket sealing
surface (Fig. 54) of oil and grime.
(6) Install new filter (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - INSTALLATION).
INSTALLATION
(1) Lightly lubricate oil filter gasket with engine
oil or chassis grease.
(2) Thread filter onto adapter nipple. When gasket
makes contact with sealing surface, (Fig. 54) hand
tighten filter one full turn, do not over tighten.
(3) Add oil (Refer to 9 - ENGINE/LUBRICATION/
OIL - STANDARD PROCEDURE).
OIL PAN
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Remove engine oil dipstick.
(3) Raise vehicle.
(4) Drain engine oil.
(5) Remove exhaust pipe.
(6) Remove left engine to transmission strut.
(7) Loosen the right side engine support bracket
cushion through-bolt nut and raise the engine
slightly. Remove oil pan by sliding backward and out.
(8) Remove the one-piece gasket.
Fig. 53 Oil Filter RemovalÐTypical
1 - ENGINE OIL FILTER
2 - OIL FILTER WRENCH
Fig. 54 Oil Filter Sealing SurfaceÐTypical
1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER
9 - 48 ENGINE 3.9LBR/BE
OIL (Continued)

CLEANING
Clean the block and pan gasket surfaces.
Trim or remove excess sealant film in the rear
main cap oil pan gasket groove.DO NOT remove
the sealant inside the rear main cap slots.
If present, trim excess sealant from inside the
engine.
Clean oil pan in solvent and wipe dry with a clean
cloth.
Clean oil screen and pipe thoroughly in clean sol-
vent. Inspect condition of screen.
INSPECTION
Inspect oil drain plug and plug hole for stripped or
damaged threads. Repair as necessary.
Inspect oil pan mounting flange for bends or distor-
tion. Straighten flange, if necessary.
INSTALLATION
(1) Clean the block and pan gasket surfaces.
(2) Fabricate four alignment dowels from 5/16 X 1
1/2 inch bolts. Cut the head off the bolts and cut a
slot into the top of the dowel. This will allow easier
installation and removal with a screwdriver (Fig. 55).
(3)
Install the dowels in the cylinder block (Fig. 56).
(4) Apply small amount of MopartSilicone Rubber
Adhesive Sealant, or equivalent, in the corner of the
cap and the cylinder block.
(5) Slide the one-piece gasket over the dowels and
onto the block.
(6) Position the oil pan over the dowels and onto
the gasket.
(7) Install the oil pan bolts. Tighten the bolts to 24
N´m (215 in. lbs.) torque.
(8)
Remove the dowels. Install the remaining oil pan
bolts. Tighten these bolts to 24 N´m (215 in. lbs.) torque.
(9) Lower the engine into the support cushion
brackets and tighten the through-bolt nut to the
proper torque.(10) Install the drain plug. Tighten drain plug to
34 N´m (27 ft. lbs.) torque.
(11) Install the engine to transmission strut.
(12) Install exhaust pipe.
(13) Lower vehicle.
(14) Install dipstick.
(15) Connect the negative cable to the battery.
(16) Fill crankcase with oil to proper level.
OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
The 2±wire, electrical/mechanical engine oil pres-
sure sensor (sending unit) is located in an engine oil
pressure gallery.
OPERATION
The oil pressure sensor uses two circuits. They are:
²
A signal to the PCM relating to engine oil pressure
²A sensor ground through the PCM's sensor return
The oil pressure sensor returns a voltage signal
back to the PCM relating to engine oil pressure. This
signal is then transferred (bussed) to the instrument
panel on a CCD bus circuit to operate the oil pres-
sure gauge and the check gauges lamp. Ground for
the sensor is provided by the PCM through a low-
noise sensor return.
Fig. 55 Fabrication of Alignment Dowels
1 - 5/16º X 1óº BOLT
2 - DOWEL
3 - SLOT
Fig. 56 Position of Dowels in Cylinder Block
1 - DOWEL
2 - DOWEL
3 - DOWEL
4 - DOWEL
BR/BEENGINE 3.9L 9 - 49
OIL PAN (Continued)

DIAGNOSIS AND TESTINGÐINTAKE
MANIFOLD LEAKAGE
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS, OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water at the suspected
leak area.
(3) If a change in RPMs, 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 cross-over gaskets.(18) Remove the throttle body (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/THROTTLE BODY -
REMOVAL).
(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 the plenum pan was removed, position a new
gasket and install the plenum pan (Fig. 67). Tighten
bolts in the following sequence:
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 bolts to 9.5 N´m (84 in. lbs.)
(2) Install the flange gaskets. Ensure that the ver-
tical port alignment tab is resting on the deck face of
the block. Also the horizontal alignment tabs must be
in position with the mating cylinder head gasket tabs
(Fig. 69). The words MANIFOLD SIDE should be vis-
ible on the center of each flange gasket.
Fig. 67 Plenum Pan Bolt Tightening Sequence
BR/BEENGINE 3.9L 9 - 53
INTAKE MANIFOLD (Continued)

(8) Install closed crankcase ventilation and evapo-
ration control systems.
(9) Connect the coil wires.
(10) Connect the heat indicator sending unit wire.
(11) Connect the heater hoses and bypass hose.
(12) Install distributor cap and wires.
(13) Hook up the return spring.
(14) 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.
(15) Install the fuel lines (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE).
(16) Install the accessory drive bracket and A/C
Compressor (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/A/C COMPRESSOR -
INSTALLATION).
(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 air cleaner.
(19) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(20) Connect the negative cable to the battery.
EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifolds (Fig. 71) 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) Disconnect the exhaust pipe from the exhaust
manifold (Refer to 11 - EXHAUST SYSTEM/EX-
HAUST PIPE - REMOVAL).
(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. 72).
(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. 72).
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.
Fig. 71 Exhaust ManifoldsÐ3.9L Engine
1 - EXHAUST MANIFOLD (RIGHT)
2 - EXHAUST MANIFOLD (LEFT)
3 - BOLTS & WASHERS
4 - NUTS & WASHERS
BR/BEENGINE 3.9L 9 - 55
INTAKE MANIFOLD (Continued)