drain bolt DODGE RAM 2001 Service Owner's Guide

(9) Re-install the thermostat cover onto the oil
cooler and install the snap-ring.
(10) Re-connect the oil cooler to the transmission
cooler lines.
(11) Turn pump ON for two to three minutes to
flush cooler(s) and lines.
NOTE: This flushes the bypass circuit of the cooler
only.
(12) Turn pump OFF.
(13) Remove the thermostat cover from the oil
cooler.
(14) Install Special Tool Cooler Plug 8414 into the
transmission oil cooler.
(15) Re-install the thermostat cover onto the oil
cooler and install the snap-ring.
(16) Turn pump ON for two to three minutes to
flush cooler(s) and lines.
NOTE: This flushes the main oil cooler core pas-
sages only.
(17) Turn pump OFF.
(18) Remove the thermostat cover from the oil
cooler.
(19) Remove Special Tool Cooler Plug 8414 from
the transmission oil cooler.
(20) Install a new thermostat spring, thermostat,
cover, and snap-ring into the transmission oil cooler.
(Refer to 7 - COOLING/TRANSMISSION/TRANS
COOLER - ASSEMBLY)
(21) Install the transmission oil cooler onto the
vehicle. (Refer to 7 - COOLING/TRANSMISSION/
TRANS COOLER - INSTALLATION)
(22) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(23) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(24) Place CLEAR suction line into a one quart
container of MopartATF +4, type 9602, Automatic
Transmission fluid.
(25) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(26) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
REMOVALÐAIR TO OIL COOLER
(1) Remove front bumper.
(2) Place a drain pan under the oil cooler.
(3) Raise the vehicle.
(4) Disconnect the oil cooler quick-connect fittings
from the transmission lines.(5) Remove the charge air cooler-to-oil cooler bolt
(Fig. 8).
(6) Remove two mounting nuts.
(7) Remove the oil cooler and line assembly
towards the front of vehicle. Cooler must be rotated
and tilted into position while removing.
REMOVALÐWATER TO OIL COOLER
CAUTION: If a leak should occur in the water-to-oil
cooler mounted to the side of the engine block,
engine coolant may become mixed with transmis-
sion fluid. Transmission fluid may also enter engine
cooling system. Both cooling system and transmis-
sion should be drained and inspected in case of oil
cooler leakage.
(1) Disconnect both battery negative cables.
(2) Remove air cleaner assembly and air cleaner
intake hoses.
(3) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(4) Disconnect coolant lines from cooler.
(5) Disconnect transmission oil lines from cooler.
Plug cooler lines to prevent oil leakage.
(6) Remove oil cooler mounting straps (Fig. 9).
Fig. 8 Auxiliary Transmission Oil CoolerÐDiesel
Engine
1 - CHARGE AIR COOLER (INTERCOOLER)
2 - QUICK-CONNECT FITTINGS (2)
3 - MOUNTING NUTS (2)
4 - MOUNTING BOLT
5 - TRANSMISSION OIL COOLER
BR/BETRANSMISSION 7 - 87
TRANS COOLER - 5.9L DIESEL (Continued)

(7) Lift oil cooler off of mounting bracket.
(8) If replacing cooler, make sure to transfer con-
verter drain back valve to new cooler.INSTALLATIONÐAIR TO OIL COOLER
(1) Carefully position the oil cooler assembly to the
vehicle.
(2) Install two nuts and one bolt. Tighten to 11
N´m (95 in. lbs.) torque.
(3) Connect the quick-connect fittings to the trans-
mission cooler lines.
(4) Install front bumper.
(5) Start the engine and check all fittings for
leaks.
(6) Check the fluid level in the automatic trans-
mission (Refer to 21 - TRANSMISSION/TRAN-
SAXLE/AUTOMATIC - 47RE/FLUID - STANDARD
PROCEDURE).
INSTALLATION
(1) Position oil cooler on bracket.
(2) Install mounting straps.
(3) Connect transmission oil lines to cooler.
(4) Connect coolant hoses to cooler.
(5) Connect battery negative cables.
(6) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(7) Check transmission oil level and fill as neces-
sary (Refer to 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC - 47RE/FLUID - STANDARD
PROCEDURE).
(8) Install air cleaner assembly and air cleaner
intake hoses.
Fig. 9 Transmission Water-To- Oil CoolerÐDiesel
1 - TRANSMISSION WATER-TO-OIL COOLER
7 - 88 TRANSMISSIONBR/BE
TRANS COOLER - 5.9L DIESEL (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)

(31) 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
through-bolt into the support cushion brackets.
(2) Install an engine support fixture.
(3) Raise and support the vehicle on a hoist.
(4)Manual TransmissionInstall the transmis-
sion (Refer to 21 - TRANSMISSION/TRANSAXLE/
MANUAL - INSTALLATION).
(5) Install the starter and connect the starter
wires (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(6) Install exhaust pipe to manifold.
(7)Automatic TransmissionInstall the trans-
mission cooler line brackets on oil pan.
(8) Install engine front mount through-bolt nuts.
Tighten the nuts.
(9) Install the drain plug and tighten to 34 N´m
(25 ft. lbs.) torque.
(10) Lower the vehicle.
(11) Remove engine-lifting fixture.
(12) On Manual Transmission vehicles, install the
shift lever.
(13) Connect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(14) Connect the power steering hoses, if equipped.
(15) Connect the heater hoses.
(16) Install the distributor cap and wiring.
(17) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).(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/STARTING/STARTER
MOTOR - INSTALLATION).
(22) Install radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - INSTALLATION).
(23) Install the fan and fan shroud (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
(24) Install the washer bottle.
(25) If equipped, install the condenser (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - INSTALLATION).
(26) Install the A/C compressor with the lines
attached.
(27) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(28) Evacuate and charge the air conditioning sys-
tem, if equipped (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE).
(29) Install the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
INSTALLATION).
(30) Install the upper crossmember and top core
support.
(31) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(32) Connect the negative cable to the battery.
(33) Start engine and check for leaks.
BR/BEENGINE 3.9L 9 - 13
ENGINE 3.9L (Continued)

TORQUE
TORQUE CHART 3.9L ENGINE
DESCRIPTION N´m In. Ft.
Lbs. Lbs.
Camshaft SprocketÐBolt 68 Ð 50
Camshaft Thrust
PlateÐBolts24 210 Ð
Timing Chain Case
CoverÐ41 Ð 30
Bolts
Connecting Rod
CapÐBolts61 Ð 45
Main Bearing CapÐBolts 115 Ð 85
Crankshaft PulleyÐBolts 24 210 Ð
Cylinder HeadÐBolts
Step 1 68 Ð 50
Step 2 143 Ð 105
Cylinder Head CoverÐ
Bolts11 95 Ð
Engine Support Bracket 41 Ð 30
to Block (4wd)ÐBolts
Exhaust Manifold to
Cylinder34 Ð 25
HeadÐbolts/nuts
FlywheelÐBolts 75 Ð 55
Front InsulatorÐthrough
Bolts95 Ð 70
Front Insulator to
Support
Bracket (4wd)
ÐStud Nut 41 Ð 30
ÐThrough Bolt/Nut 102 Ð 75
Front Insulator to BlockÐ 95 Ð 70
Bolts (2wd)
GeneratorÐMounting
Bolt41 Ð 30
Intake ManifoldÐBolts Refer to Procedure
Oil PanÐBolts 24 215 Ð
Oil PanÐDrain Plug 34 Ð 25
Oil PumpÐMounting
Bolts41 Ð 30
Oil Pump CoverÐBolts 11 95 Ð
Rear Insulator to
BracketÐ68 Ð 50
DESCRIPTION N´m In. Ft.
Lbs. Lbs.
Through-Bolt (2WD)
Rear Insulator to
Crossmember41 Ð 30
Support BracketÐNut
(2WD)
Rear Insulator to 68 Ð 50
CrossmemberÐNuts
(4WD)
Rear Insulator to
Transmission68 Ð 50
Ð Bolts (4WD)
Rear Insulator BracketÐ
Bolts68 Ð 50
(4WD Automatic)
Rear Support Bracket to 41 Ð 30
Crossmember FlangeÐ
Nuts
Rear Support Plate to
Transfer41 Ð 30
CaseÐBolts
Rocker ArmÐBolts 28 Ð 21
Spark Plugs 41 Ð 30
Starter MotorÐMounting
Bolts68 Ð 50
Thermostat HousingÐ
Bolts25 225 Ð
Throttle BodyÐBolts 23 200 Ð
Torque Converter Drive
PlateÐ31 270 Ð
Bolts
Transfer Case to
Insulator204 Ð 150
Mounting PlateÐNuts
Transmission Support
Bracket68 Ð 50
ÐBolts (2WD)
Vibration DamperÐBolt 183 Ð 135
Water Pump to Timing
Chain41 Ð 30
Case CoverÐ Bolts
9 - 18 ENGINE 3.9LBR/BE
ENGINE 3.9L (Continued)

COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL
The alloy cast iron cylinder heads (Fig. 7) are held
in place by eight bolts. The spark plugs are located
at the peak of the wedge between the valves.
(1) Disconnect the battery negative cable from the
battery.
(2) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the intake manifold-to-generator
bracket support rod. Remove the generator.
(4) Remove closed crankcase ventilation system.
(5) Disconnect the evaporation control system.
(6) Remove the air cleaner, air in-let hose and res-
onator.
(7) Perform fuel system pressure release procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(8) Disconnect the fuel supply line from the fuel
rail (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
QUICK CONNECT FITTING - STANDARD PROCE-
DURE).
(9) Disconnect accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(10) Remove distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect coolant temperature sending unit
wire.
(13) Disconnect heater hoses and bypass hose.
(14) Disconnect the vacuum supply hoses from the
intake manifold.
(15) Disconnect the fuel injector harness and
secure out of the way.
(16) Remove cylinder head covers and gaskets
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).(17) Remove intake manifold and throttle body as
an assembly. Discard the flange side gaskets and the
front and rear cross-over gaskets.
(18) Remove exhaust manifolds (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
REMOVAL).
(19) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations.
(20) Remove the head bolts from each cylinder
head and remove cylinder heads. Discard the cylin-
der head gasket.
(21) Remove spark plugs.
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
INSPECTION
Inspect all surfaces with a straightedge if there is
any reason to suspect leakage. If out-of-flatness
exceeds 0.00075mm (0.0001in.) times the span length
in any direction, either replace head or lightly
machine the head surface.
FOR EXAMPLE:ÐA 305 mm (12 in.) span is
0.102 mm (0.004 in.) out-of-flat. The allowable out-of-
flat is 305 x 0.00075 (12 x 0.00075) equals 0.23 mm
(0.009 in.). This amount of out-of-flat is acceptable.
The cylinder head surface finish should be
1.78-3.00 microns (70-125 microinches).
Inspect push rods. Replace worn or bent rods.
INSTALLATION
The alloy cast iron cylinder heads (Fig. 7) are held
in place by eight bolts. The spark plugs are located
at the peak of the wedge between the valves.
(1) Position the new cylinder head gaskets onto
the cylinder block.
(2) Position the cylinder heads onto head gaskets
and cylinder block.
(3) Starting at top center, tighten all cylinder head
bolts, in sequence, to 68 N´m (50 ft. lbs.) torque (Fig.
7). Repeat procedure, tighten all cylinder head bolts
to 143 N´m (105 ft. lbs.) torque. Repeat procedure to
confirm that all bolts are at 143 N´m (105 ft. lbs.)
torque.
CAUTION: When tightening the rocker arm bolts, be
sure the piston in that cylinder is NOT at TDC. Con-
tact between the valves and piston could occur.
(4) Install push rods and rocker arm assemblies in
their original positions. Tighten the bolts to 28 N´m
(21 ft. lbs.) torque.
BR/BEENGINE 3.9L 9 - 23
CYLINDER HEAD (Continued)

(3) Using the transmission jack, lower the trans-
mission and support cushion onto the crossmember
(Fig. 49).
(4) Install the support cushion bolts and tighten to
41 N´m (30 ft. lbs.) torque.
(5) Remove the transmission jack.
(6) Lower the vehicle.
LUBRICATION
DESCRIPTION
A gear-type positive displacement pump (Fig. 50)is
mounted at the underside of the rear main bearing
cap. The pump uses a pick-up tube and screen
assembly to gather engine oil from the oil pan.
OPERATION
The pump draws oil through the screen and inlet
tube from the sump at the rear of the oil pan. The oil
is driven between the drive and idler gears and
pump body, then forced through the outlet to the
block. An oil gallery in the block channels the oil to
the inlet side of the full flow oil filter. After passing
through the filter element, the oil passes from the
center outlet of the filter through an oil gallery that
channels the oil up to the main gallery, which
extends the entire length on the right side of the
block. The oil then goes down to the No. 1 main bear-
ing, back up to the left side of the block, and into the
oil gallery on the left side of the engine.
Galleries extend downward from the main oil gal-
lery to the upper shell of each main bearing. The
crankshaft is drilled internally to pass oil from the
main bearing journals to the connecting rod journals.
Each connecting rod bearing has half a hole in it, oil
passes through the hole when the rods rotate and the
hole lines up, oil is then thrown off as the rod
rotates. This oil throwoff lubricates the camshaft
lobes, distributor drive gear, cylinder walls, and pis-
ton pins.The hydraulic valve tappets receive oil directly
from the main oil gallery. The camshaft bearings
receive oil from the main bearing galleries. The front
camshaft bearing journal passes oil through the cam-
shaft sprocket to the timing chain. Oil drains back to
the oil pan under the No. 1 main bearing cap.
The oil supply for the rocker arms and bridged
pivot assemblies is provided by the hydraulic valve
tappets, which pass oil through hollow push rods to a
hole in the corresponding rocker arm. Oil from the
rocker arm lubricates the valve train components.
The oil then passes down through the push rod guide
holes and the oil drain-back passages in the cylinder
head, past the valve tappet area, and then returns to
the oil pan (Fig. 51).
Fig. 50 Positive Displacement Oil PumpÐTypical
1 - INNER ROTOR AND SHAFT
2 - BODY
3 - DISTRIBUTOR DRIVESHAFT (REFERENCE)
4 - COTTER PIN
5 - RETAINER CAP
6 - SPRING
7 - RELIEF VALVE
8 - LARGE CHAMFERED EDGE
9 - BOLT
10 - COVER
11 - OUTER ROTOR
BR/BEENGINE 3.9L 9 - 45
REAR MOUNT (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)