drain bolt DODGE RAM 2001 Service Service Manual

(5) Assemble exhaust pipe to manifold and secure
with bolts, nuts and retainers. Tighten the bolts and
nuts to 34 N´m (25 ft. lbs.) torque.
(6) Lower the vehicle.
(7) Connect the negative cable to the battery.
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(1) Disconnect the battery negative cable.
(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 water pump (Refer to 7 - COOLING/
ENGINE/WATER PUMP - REMOVAL).
(5) Remove power steering pump (Refer to 19 -
STEERING/PUMP - REMOVAL).
(6) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(7) Loosen oil pan bolts and remove the front bolt
at each side.
(8) Remove the cover bolts.
(9) Remove chain case cover and gasket using
extreme caution to avoid damaging oil pan gasket.
(10) From the inside of the cover tap the front
crankshaft oil seal outward. Be careful not to damage
the timing cover sealing surface.
INSTALLATION
(1) Be sure mating surfaces of chain case cover
and cylinder block are clean and free from burrs.
(2) Using a new cover gasket, carefully install
chain case cover to avoid damaging oil pan gasket.
Use a small amount of MopartGEN II Silicone Rub-
ber Adhesive Sealant, or equivalent, at the joint
between timing chain cover gasket and the oil pan
gasket. Finger tighten the timing chain cover bolts at
this time.
CAUTION: If chain cover is replaced for any reason,
be sure the oil hole (passenger side of cover) is
plugged.
NOTE: Special Tool 6635 must be used to align
cover and seal with crankshaft.
(3) Position the special tool 6635 onto the crank-
shaft (Fig. 73).
(4) Tighten chain case cover bolts to 41 N´m (30 ft.
lbs.) torque. Tighten oil pan bolts to 24 N´m (215 in.
lbs.) torque.
(5) Remove special tool 6635.
(6) Inspect the seal flange on the vibration
damper.
(7) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
Fig. 72 Engine Exhaust Manifold InstallationÐ3.9L
Engine
1 - EXHAUST MANIFOLD (RIGHT)
2 - EXHAUST MANIFOLD (LEFT)
3 - BOLTS & WASHERS
4 - NUTS & WASHERS
Fig. 73 Position Special Tool 6635 onto Crankshaft
1 - SPECIAL TOOL 6635
2 - OIL SEAL
3 - TIMING CHAIN COVER
9 - 56 ENGINE 3.9LBR/BE
EXHAUST MANIFOLD (Continued)

(8) Install water pump (Refer to 7 - COOLING/EN-
GINE/WATER PUMP - INSTALLATION).
(9) Install power steering pump (Refer to 19 -
STEERING/PUMP - INSTALLATION).
(10) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(11) Install the cooling system fan (Refer to 7 -
COOLING/ENGINE/FAN DRIVE VISCOUS
CLUTCH - INSTALLATION).
(12) Position the fan shroud and install the bolts.
Tighten the bolts to 11 N´m (95 in. lbs.) torque.
(13) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(14) Connect the negative cable to the battery.
TIMING BELT/CHAIN
TENSIONER
DESCRIPTION
The timing chain tensioner is a stamped steel con-
stant tension mechanical design. It is mounted to the
front of the engine, behind the timing chain drive.
OPERATION
The timing chain tension is maintained by routing
the timing chain through the tensioner assembly. A
nylon covered spring steel arm presses on the timing
chain maintaining the correct chain tension.
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
(1) Disconnect battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(4) Rotate crankshaft to align timing marks (Fig.
75) to #1 TDC.
(5) Remove camshaft sprocket attaching bolt and
remove timing chain with crankshaft and camshaft
sprockets.
(6) Slip crankshaft sprocket onto crankshaft and
compress tensioner shoe by placing a large screw-
driver between crankshaft sprocket and tensioner
shoe (Fig. 74). Compress shoe until hole in shoe lines
up with hole in bracket. Slide a suitable pin into the
holes (Fig. 74) and remove screwdriver.(7) If tensioner assembly is to be replaced, remove
the three tensioner to block bolts and remove ten-
sioner assembly.
Fig. 74 Compressing Tensioner For Chain
Installation
1 - SCREWDRIVER
2 - INSERT PIN HERE
Fig. 75 Alignment of Timing Marks
1 - TIMING MARKS
BR/BEENGINE 3.9L 9 - 57
TIMING BELT / CHAIN COVER(S) (Continued)

(5) Remove the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
REMOVAL).
(6) Remove the washer bottle from the fan shroud.
(7) Remove the viscous fan/drive (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(8) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(9) Remove the upper crossmember and top core
support.
(10) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(11) Remove the A/C compressor with the lines
attached. Secure compressor out of the way.
(12) Remove generator assembly (Refer to 8 -
ELECTRICAL/CHARGING/GENERATOR - REMOV-
AL).
(13) Remove the air cleaner resonator and duct
work as an assembly.
(14) Disconnect the throttle linkage (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - REMOVAL).
(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).
(21) Disconnect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(22) On Manual Transmission vehicles, remove the
shift lever (Refer to 21 - TRANSMISSION/TRAN-
SAXLE/MANUAL/SHIFT COVER - REMOVAL).
(23) Raise and support the vehicle on a hoist and
drain the engine oil.
(24) Remove engine front mount thru-bolt nuts.
(25) Disconnect the transmission oil cooler lines
from their retainers at the oil pan bolts.
(26) Disconnect exhaust pipe at manifolds.
(27) Disconnect the starter wires. Remove starter
motor (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - REMOVAL).
(28) Remove the dust shield and transmission
inspection cover.
(29) Remove drive plate to converter bolts (Auto-
matic transmission equipped vehicles).(30) Remove transmission bell housing to engine
block bolts.
(31) Lower the vehicle.
(32) Install an engine lifting fixture.
(33) Separate engine from transmission, 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 engine lifting device.
(3) Lower engine into compartment and align
engine with transmission:
²Manual Transmission: Align clutch disc assem-
bly (if disturbed). Install transmission input shaft
into clutch disc while mating engine and transmis-
sion surfaces. Install two transmission to engine
block mounting bolts finger tight.
²Automatic Transmission: Mate engine and trans-
mission and install two transmission to engine block
mounting bolts finger tight.
(4) Lower engine assembly until engine mount
through bolts rest in mount perches.
(5) Install remaining transmission to engine block
mounting bolts and tighten.
(6) Tighten engine mount through bolts.
(7) Install drive plate to torque converter bolts.
(Automatic transmission models)
(8) Install the dust shield and transmission cover.
(9) Install the starter and connect the starter
wires (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(10) Install exhaust pipe to manifold.
(11) Install the transmission cooler line brackets to
the oil pan.
(12) Install the drain plug and tighten to 34 N´m
(25 ft. lbs.) torque.
(13) Lower the vehicle.
(14) Remove engine lifting fixture.
(15) On Manual Transmission vehicles, install the
shift lever (Refer to 21 - TRANSMISSION/TRAN-
SAXLE/MANUAL/SHIFT COVER - INSTALLA-
TION).
(16) Connect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(17) Connect the power steering hoses, if equipped.
(18) Connect the heater hoses.
(19) Install the distributor cap and wiring.
(20) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).
9 - 70 ENGINE 5.2LBR/BE
ENGINE 5.2L (Continued)

TORQUE
TORQUE CHART 5.2L ENGINE
DESCRIPTION N´m In. Ft.
Lbs. Lbs.
Camshaft SprocketÐBolt 68 Ð 50
Camshaft Thrust PlateÐBolts 24 210 Ð
Chain Case CoverÐBolts 41 Ð 30
Connecting Rod CapÐBolts 61 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 CoverÐBolts 11 95 Ð
Engine Support Bracket to
BlockÐ41 Ð 30
Bolts (4WD)
Exhaust Manifold to Cylinder
HeadÐ34 Ð 25
Bolts/Nuts
FlywheelÐBolts 75 Ð 55
Front InsulatorÐThrough
bolt/nut95 Ð 70
Front Insulator to Support
BracketÐ
Stud Nut (4WD) 41 Ð 30
Through Bolt/Nut 102 Ð 75
Front Insulator to BlockÐ 95 Ð 70
Bolts (2WD)
GeneratorÐMounting Bolts 41 Ð 30
Intake ManifoldÐBolts Refer to Procedure
Oil PanÐBolts 24 215 Ð
Oil PanÐDrain Plug 34 Ð 25
Oil PumpÐMounting Bolts 41 Ð 30
Oil Pump CoverÐBolts 11 95 Ð
Rear Insulator to BracketÐ
Through68 Ð 50
Bolt (2WD)
Rear Insulator to
Crossmember41 Ð 30
Support BracketÐNut (2WD)
Rear Insulator to
CrossmemberÐ68 Ð 50
Nuts (4WD)
DESCRIPTION N´m In. Ft.
Lbs. Lbs.
Rear Insulator to
TransmissionÐ68 Ð 50
Bolts (4WD)
Rear Insulator BracketÐBolts 68 Ð 50
(4WD Automatic)
Rear Support Plate to
Transfer Case41 Ð 30
ÐBolts
Rocker ArmÐBolts 28 Ð 21
Spark Plugs 41 Ð 30
Starter MotorÐMounting
Bolts68 Ð 50
Thermostat HousingÐBolts 25 225 Ð
Throttle BodyÐBolts 23 200 Ð
Torque Converter Drive
PlateÐBolts31 270 Ð
Transfer Case to Insulator
Mounting204 Ð 150
PlateÐNuts
Transmission Support
BracketÐ68 Ð 50
Bolts (2WD)
Vibration DamperÐBolt 183 Ð 135
Water Pump to Timing Chain
Case41 Ð 30
CoverÐBolts
9 - 76 ENGINE 5.2LBR/BE
ENGINE 5.2L (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
(1) Disconnect the battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the air cleaner resonator and duct
work.
(4) Remove the intake manifold-to-generator
bracket support rod. Remove the generator.
(5) Remove closed crankcase ventilation system.
(6) Disconnect the evaporation control system.
(7) Perform the Fuel System Pressure Release pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY - STANDARD PROCEDURE). Disconnect the
fuel supply line (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(8) Disconnect accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(9) Remove distributor cap and wires.
(10) Disconnect the coil wires.
(11) Disconnect heat indicator sending unit wire.
(12) Disconnect heater hoses and bypass hose.
(13) Remove cylinder head covers and gaskets
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(14) Remove intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL) and throttle body as an assembly. Dis-
card the flange side gaskets and the front and rear
cross-over gaskets.
(15) Remove exhaust manifolds (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
REMOVAL).
(16) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations.(17) Remove the head bolts from each cylinder
head and remove cylinder heads. Discard the cylin-
der head gasket.
(18) 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
(1) Clean all surfaces of cylinder block and cylin-
der heads.
(2) Clean cylinder block front and rear gasket sur-
faces using a suitable solvent.
(3) Position new cylinder head gaskets onto the
cylinder block.
(4) Position cylinder heads onto head gaskets and
cylinder block.
(5) Starting at top center, tighten all cylinder head
bolts, in sequence (Fig. 6).
Fig. 6 Cylinder Head Bolt Tightening Sequence
9 - 80 ENGINE 5.2LBR/BE
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. 48)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. 49).
Fig. 48 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
9 - 102 ENGINE 5.2LBR/BE
REAR MOUNT (Continued)

(5) Remove dipstick, with handle held above the
tip, take oil level reading.
(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. 51).
(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. 52) 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 thru-bolt nut and raise the engine slightly.
Remove oil pan by sliding backward and out.
(8) Remove the one-piece gasket.
Fig. 51 Oil Filter RemovalÐTypical
1 - ENGINE OIL FILTER
2 - OIL FILTER WRENCH
Fig. 52 Oil Filter Sealing SurfaceÐTypical
1 - SEALING SURFACE
2 - RUBBER GASKET
3 - OIL FILTER
BR/BEENGINE 5.2L 9 - 105
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) 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.
(3) If present, trim excess sealant from inside the
engine.
(4) Fabricate 4 alignment dowels from 5/16x11/2
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. 53).
(5) Install the dowels in the cylinder block (Fig.
54).(6) Apply small amount of MopartSilicone Rubber
Adhesive Sealant, or equivalent in the corner of the
cap and the cylinder block.
(7) Slide the one-piece gasket over the dowels and
onto the block.
(8) Position the oil pan over the dowels and onto
the gasket.
(9) Install the oil pan bolts. Tighten the bolts to 24
N´m (215 in. lbs.) torque.
(10) Remove the dowels. Install the remaining oil
pan bolts. Tighten these bolts to 24 N´m (215 in. lbs.)
torque.
(11) Lower the engine into the support cushion
brackets and tighten the thru bolt nut to the proper
torque.
(12) Install the drain plug. Tighten drain plug to
34 N´m (25 ft. lbs.) torque.
(13) Install the engine to transmission strut.
(14) Install exhaust pipe.
(15) Lower vehicle.
(16) Install dipstick.
(17) Connect the negative cable to the battery.
(18) Fill crankcase with oil to proper level.
Fig. 53 Fabrication of Alignment Dowels
1 - 5/16º X 1óº BOLT
2 - DOWEL
3 - SLOT
Fig. 54 Position of Dowels in Cylinder Block
1 - DOWEL
2 - DOWEL
3 - DOWEL
4 - DOWEL
9 - 106 ENGINE 5.2LBR/BE
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 bolts and lift the
throttle body off the intake manifold (Fig. 65). Dis-
card the gasket.
(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.
Fig. 65 Throttle Body Assembly
1 - FUEL RAIL ASSEMBLY
2 - FUEL RAIL MOUNTING BOLTS
3 - FUEL RAIL CONNECTING HOSES
9 - 110 ENGINE 5.2LBR/BE
INTAKE MANIFOLD (Continued)

(5) Remove the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
REMOVAL).
(6) Remove the washer bottle from the fan shroud.
(7) Remove the viscous fan/drive (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(8) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(9) Remove the upper crossmember and top core
support.
(10) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(11) Remove the A/C compressor with the lines
attached. Secure compressor out of the way.
(12) Remove generator assembly (Refer to 8 -
ELECTRICAL/CHARGING/GENERATOR - REMOV-
AL).
(13) Remove the air cleaner resonator and duct
work as an assembly.
(14) Disconnect the throttle linkage (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - REMOVAL).
(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).
(21) Disconnect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(22) On Manual Transmission vehicles, remove the
shift lever (Refer to 21 - TRANSMISSION/TRAN-
SAXLE/MANUAL/SHIFT COVER - REMOVAL).
(23) Raise and support the vehicle on a hoist and
drain the engine oil.
(24) Remove engine front mount thru-bolt nuts.
(25) Disconnect the transmission oil cooler lines
from their retainers at the oil pan bolts.
(26) Disconnect exhaust pipe at manifolds.
(27) Disconnect the starter wires. Remove starter
motor (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - REMOVAL).
(28) Remove the dust shield and transmission
inspection cover.
(29) Remove drive plate to converter bolts (Auto-
matic transmission equipped vehicles).(30) Remove transmission bell housing to engine
block bolts.
(31) Lower the vehicle.
(32) Install an engine lifting fixture.
(33) Separate engine from transmission, 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 engine lifting device.
(3) Lower engine into compartment and align
engine with transmission:
²Manual Transmission: Align clutch disc assem-
bly (if disturbed). Install transmission input shaft
into clutch disc while mating engine and transmis-
sion surfaces. Install two transmission to engine
block mounting bolts finger tight.
²Automatic Transmission: Mate engine and trans-
mission and install two transmission to engine block
mounting bolts finger tight.
(4) Lower engine assembly until engine mount
through bolts rest in mount perches.
(5) Install remaining transmission to engine block
mounting bolts and tighten.
(6) Tighten engine mount through bolts.
(7) Install drive plate to torque converter bolts.
(Automatic transmission models)
(8) Install the dust shield and transmission cover.
(9) Install the starter and connect the starter
wires (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(10) Install exhaust pipe to manifold.
(11) Install the transmission cooler line brackets to
the oil pan.
(12) Install the drain plug and tighten to 34 N´m
(25 ft. lbs.) torque.
(13) Lower the vehicle.
(14) Remove engine lifting fixture.
(15) On Manual Transmission vehicles, install the
shift lever (Refer to 21 - TRANSMISSION/TRAN-
SAXLE/MANUAL/SHIFT COVER - INSTALLA-
TION).
(16) Connect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(17) Connect the power steering hoses, if equipped.
(18) Connect the heater hoses.
(19) Install the distributor cap and wiring.
(20) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).
BR/BEENGINE 5.9L 9 - 127
ENGINE 5.9L (Continued)