body control DODGE RAM 2001 Service Manual PDF

(6) Disconnect the headlamp and dash wire har-
ness connector for the wiper motor from the wiper
motor pigtail wire connector.
(7) Disconnect the headlamp and dash wire har-
ness ground connector from the wiper motor ground
terminal.
(8) Remove the wiper module from the cowl ple-
num as a unit.
INSTALLATION
(1) Position the wiper module into the cowl ple-
num as a unit.
(2) Reconnect the headlamp and dash wire harness
ground connector to the wiper motor ground terminal
(Fig. 9).
(3) Reconnect the headlamp and dash wire harness
connector for the wiper motor to the wiper motor pig-
tail wire connector.
(4) Reach into the cowl plenum to align the wiper
module mounting bracket with the locations for the
mounting screws (Fig. 8).
(5) Install and tighten the four screws that secure
the wiper module bracket to the cowl plenum panel
and the dash panel. Tighten the screws to 8 N´m (72
in. lbs.).
(6) Reinstall the cowl plenum cover/grille panel
onto the cowl plenum. (Refer to 23 - BODY/EXTERI-
OR/COWL GRILLE - INSTALLATION).
(7) Reinstall the wiper arms onto the wiper pivots.
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER ARMS - INSTALLATION).
(8) Reconnect the battery negative cable.
WIPER RELAY
DESCRIPTION
The wiper relay (or intermittent wipe relay) is
located in the Power Distribution Center (PDC) near
the battery in the engine compartment. See the fuse
and relay layout label affixed to the inside surface of
the PDC cover for wiper relay identification and loca-
tion. The wiper relay is a conventional International
Standards Organization (ISO) micro relay. Relays
conforming to the ISO specifications have common
physical dimensions, current capacities, terminal pat-
terns, and terminal functions. The relay is contained
within a small, rectangular, molded plastic housing.
The relay is connected to all of the required inputs
and outputs through its PDC receptacle by five male
spade-type terminals that extend from the bottom of
the relay base. The ISO designation for each termi-
nal is molded into the base adjacent to the terminal.
The ISO terminal designations are as follows:
²30 (Common Feed)- This terminal is con-
nected to the movable contact point of the relay.
²85 (Coil Ground)- This terminal is connected
to the ground feed side of the relay control coil.
²86 (Coil Battery)- This terminal is connected
to the battery feed side of the relay control coil.
²87 (Normally Open)- This terminal is con-
nected to the normally open fixed contact point of the
relay.
²87A (Normally Closed)- This terminal is con-
nected to the normally closed fixed contact point of
the relay.
The wiper relay cannot be adjusted or repaired. If
the relay is damaged or faulty, it must be replaced.
OPERATION
The wiper relay (or intermittent wipe relay) is an
electromechanical switch that uses a low current
input from the Central Timer Module (CTM) to con-
trol a high current output to the low speed brush of
the wiper motor. The movable common feed contact
point is held against the fixed normally closed con-
tact point by spring pressure. When the relay coil is
energized, an electromagnetic field is produced by the
coil windings. This electromagnetic field draws the
movable relay contact point away from the fixed nor-
mally closed contact point, and holds it against the
fixed normally open contact point. When the relay
coil is de-energized, spring pressure returns the mov-
able contact point back against the fixed normally
closed contact point. A resistor or diode is connected
in parallel with the relay coil in the relay, and helps
to dissipate voltage spikes and electromagnetic inter-
ference that can be generated as the electromagnetic
field of the relay coil collapses.
Fig. 9 Wiper Module Electrical Connections
1 - GROUND CONNECTOR
2 - WIPER MOTOR CONNECTOR
3 - GROUND TERMINAL
BR/BEWIPERS/WASHERS 8R - 15
WIPER MODULE (Continued)

8W-90 CONNECTOR/GROUND LOCATIONS
TABLE OF CONTENTS
page
CONNECTOR/GROUND LOCATIONS
DESCRIPTION............................1
CONNECTOR/GROUND
LOCATIONS
DESCRIPTION
This section provides illustrations identifying con-
nector and ground locations in the vehicle. A connec-tor and ground index is provided. Use the wiring
diagrams in each section for connector and ground
identification. Refer to the index for the proper figure
number. For items that are not shown in this section
N/S is placed in the Fig. column.
Connector Name/Number Color Location Fig.
4WD Switch BK On Front Axle N/S
A/C Compressor Clutch BK Rear of A/C Compressor 4,5,6,8
A/C Heater Control BK Center of Instrument Panel 25
A/C Heater Temperature Select NAT Center of Instrument Panel 25
A/C High Pressure Switch BK At A/C Compressor 4,5,6,8
A/C Low Pressure Switch BK Top of A/C Accumulator 1,2
Accelerator Pedal Position Sensor (Diesel) Left Front of Engine 10,11
Aftermarket Trailer Tow Connector Rear of Vehicle N/S
Airbag Control Module Center of I.P. at Airbag Control
Module23
Ambient Temperature Sensor BK Radiator Left Support N/S
Ash Receiver Lamp Center of Instrument Panel 26
Back-up Lamp Switch BK Top of Transmission 13
Battery Temperature Sensor BK Below Battery Tray 16
Blend Door Actuator Center of Instrument Panel N/S
Blower Motor BK Bottom Right of Instrument Panel 23
Blower Motor Resistor Block BK Bottom Right of Instrument Panel 26
Brake Lamp Switch Brake Pedal Arm 23,24
Brake Pressure Switch At Master Cylinder 14
Bypass Jumper GN Top Of Clutch Pedal 27
C105 Rear of Front Bumper N/S
C106 BK Rear of Front Bumper 17
C114 BK Radiator Left Support 15
C125 (Diesel) BK Left Rear of Engine Compartment 2
C126 (Diesel) GY Left Rear of Engine Compartment 2
C129 BK Above Left Front Body Cushion 15,22
C130 At Power Distribution Center 1,2
C134 BK Left Cowl 23,25,27
BR/BE8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 1

Connector Name/Number Color Location Fig.
C203 Left Cowl 23,25
C204 Left Cowl 25
C205 Instrument Panel Center Support N/S
C206 Left Cowl 23,25
C237 Bottom Right of Instrument Panel 23,26
C303 BK Below Driver's Seat 18
C308 Center Rear of Headliner N/S
C329 BK Below Right Tail Lamp 21
C333 BK Below Left Tail Lamp 21
C342 BK Left Rear of Frame 21
C343 BK Left Rear of Frame 21
C345 Right Door N/S
C346 Right Door N/S
C347 Left Door 20
C348 Left Door 20
C352 BK Left A-Pillar 20
C353 BK Right A-Pillar 20
C358 NAT Left Side Instrument Panel 20,23,27
C359 Heated Seat To Body Wiring 18
C360 Below Driver's Seat 18
C361 Left Rear Speaker Wiring N/S
C364 Right Rear Speaker Wiring N/S
C365 Under Passenger Power Seat N/S
Camshaft Position Sensor (V6, V8) Near of Distributor 3
Camshaft Position Sensor (V10) Front of Engine 6
Camshaft Position Sensor (Diesel) Left Front of Engine 10
Cargo Lamp No. 1 BK Rear of Lamp N/S
Cargo Lamp No. 2 BK Rear of Lamp N/S
Center High Mounted Stop Lamp No. 1 BK Rear of Cab 18
Center High Mounted Stop Lamp No. 2 BK Rear of Cab 18
Center Identification Lamp BK Behind Front of Headliner 20
Central Timer Module C1 Left Side Under Instrument Panel 23,24
Central Timer Module C2 Left Side Under Instrument Panel 23,24
Cigar Lighter NAT Center of Instrument Panel 25
Clockspring No.1 Steering Column 24
Clockspring No.2 Steering Column 24
Clockspring No.3 Steering Column 24
Clutch Pedal Position Switch BK Top of Clutch Pedal 27
Controller Anti-Lock Brake C1 Left Fender Side Shield 14
Controller Anti-Lock Brake C2 Left Fender Side Shield 14
Crankshaft Position Sensor (V6, V8) Rear of Engine Block 3
Crankshaft Position Sensor (V10 Right Side of Engine Block 6
8W - 90 - 2 8W-90 CONNECTOR/GROUND LOCATIONSBR/BE
CONNECTOR/GROUND LOCATIONS (Continued)

Connector Name/Number Color Location Fig.
G100 Left Fender Side Shield 16
G101 Left Fender Side Shield 16
G102 Left Fender Side Shield (RWAL
Ground)N/S
G103 Near T/O for Wiper Motor 14
G105 Front of Engine (Engine Ground) 4,5,6,9
G107 (Diesel) Left Rear of Engine 10
G113 (Diesel) Primary Battery Engine Ground N/S
G114 Battery Engine Ground N/S
G115 (Diesel) Primary Battery Body Ground N/S
G116 Battery Frame Ground N/S
G117 (Diesel) Auxilary Battery Engine Ground N/S
G118 (Diesel) Primary Frame Ground N/S
G120 (Diesel) Auxilary Battery Body Ground N/S
G200 Left Cowl 24
G201 Instrument Panel Right Center
Support23,25
G300 Left Lower Cowl 20
G301 Below Left Rear Speaker 18
G302 At Overhead Console 20
Generator BK Front of Engine 7,8
Glove Box Lamp At Glove Box 23
Headlamp Switch C1 BK Left Side of Instrument Panel 23,26
Headlamp Switch C2 Left Side of Instrument Panel 23,26
Heated Mirror Switch Center of Instrument Panel 25
High Note Horn BK Front Bumper Right Support 17
Idle Air Control Motor BK On Throttle Body 9
Ignition Coil GY Right Front of Engine 4,5,9
Ignition Coil 4 Pack BK Right Side of Engine 9
Ignition Coil 6 Pack BK Right Side of Engine 9
Ignition Switch C1 Steering Column 24
Ignition Switch C2 Steering Column 24
Instrument Cluster C1 Rear of Instrument Cluster 23
Instrument Cluster C2 Rear of Instrument Cluster 23
Intake Air Heater Relay Left Fender Side Shield 16
Intake Air Temperature Sensor (Diesel) Left Rear of Engine 10
Intake Air Temperature Sensor (Gas) GY On Intake Manifold 4,5,6
Joint Connector No. 1 In Power Distribution Center N/S
Joint Connector No. 2 In Power Distribution Center N/S
Joint Connector No. 3 Front Bumper Right support 17
Joint Connector No. 4 Left Front Engine Compartment 16
Joint Connector No. 5 NAT Left Side of Instrument Panel 24
Joint Connector No. 6 NAT Left Side of Instrument Pane 24
8W - 90 - 4 8W-90 CONNECTOR/GROUND LOCATIONSBR/BE
CONNECTOR/GROUND LOCATIONS (Continued)

Connector Name/Number Color Location Fig.
Joint Connector No. 7 NAT Left Side of Instrument Pane 24
Joint Connector No. 8 NAT Center of Instrument Panel 23
Junction Block C1 BL Left Cowl 27
Junction Block C2 NAT Left Cowl 27
Junction Block C3 Left Cowl 20
Junction Block C4 BR Left Cowl 25
Junction Block C5 GN Left Cowl 25
Junction Block C6 BK Left Cowl 25
Junction Block C7 LTGY Left Cowl 25
Junction Block C8 OR Left Cowl 25
Junction Block C9 NAT Left Cowl 25
Leak Detection Pump BK Right Fender Side Shield 17
Left Back-Up Lamp GY Rear of Lamp N/S
Left Fog Lamp BK Rear of Fog Lamp N/S
Left Front Door Speaker (Premium) BK In Door 19
Left Front Door Speaker (Standard) BK In Door 19
Left Front Fender Lamp On Fender 21
Left Front Wheel Speed Sensor BK Left Fender Side Shield 14
Left Headlamp BK At Headlamp N/S
Left License Lamp BK At Rear Bumper 21
Left Outboard Clearance Lamp BK Behind Front of Headliner 20
Left Outboard Headlamp BL At Headlamp N/S
Left Outboard Identification Lamp BK Behind Front of Headliner 20
Left Park/Turn Signal Lamp BK At Lamp N/S
Left Power Mirror BK In Door 19
Left Rear Fender Lamp BK On Fender 21
Left Rear Speaker (Premium) At B Pillar 18
Left Rear Speaker (Standard) At B Pillar 18
Left Rear Door Speaker In Door 18
Left Remote Radio Switch Steering Wheel N/S
Left Speed Control Switch Steering Wheel N/S
Left Tail/Stop Turn Signal Lamp BK At Rear Bumper 21
Left Tweeter Left A Pillar N/S
Left Visor/Vanity Lamp BK Left A-Pillar 20
Low Note Horn BK Front Bumper Right Support 17
Manifold Absolute Pressure Sensor (V6, V8) BK On Throttle Body 4,5
Manifold Absolute Pressure Sensor (V10) BK Top of Intake Manifold 9
Manifold Air Pressure Sensor (Diesel) BK Rear of Intake Manifold 10
Multi-Function Switch On Steering Column 24
Output Speed Sensor BK Left Side of Transmission 13
Overdrive Switch On Shift Lever Arm N/S
Overhead Console BK Front of Headliner 20
BR/BE8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 5
CONNECTOR/GROUND LOCATIONS (Continued)

Connector Name/Number Color Location Fig.
Right Front Wheel Speed Sensor BK Right Fender Side Shield 17
Right Headlamp BL At Headlamp N/S
Right License Lamp BK At Rear Bumper 21
Right Outboard Clearance Lamp BK Behind Front of Headliner 20
Right Outboard Headlamp At Headlamp N/S
Right Outboard Identification Lamp BK Behind Front of Headliner 20
Right Park/Turn Signal Lamp BK At Lamp N/S
Right Power Mirror BK In Door 19
Right Rear Fender Lamp On Fender 21
Right Rear Speaker Bottom of Right B Pillar 18
Right Remote Radio Switch Steering Wheel N/S
Right Speed Control Switch Steering Wheel N/S
Right Tail/Stop Turn Signal Lamp BK At Rear Bumper 21
Right Tweeter Right A Pillar N/S
Right Visor/Vanity Lamp BK Right A-Pillar N/S
Seat Belt Switch Above Left Rear Speaker 18
Tailgate Lamp On Tailgate 21
Throttle Position Sensor Throttle Body 4,5,9
Trailer Tow Connector BK On Trailer Hitch 21
Transmission Solenoid Assembly BK Side of Transmission 13
Under Hood Lamp BK Underside of Hood 15
Vehicle Speed Control Servo BK Below Battery 16
Washer Fluid Level Switch At Reservoir 16
Water In Fuel Sensor BK Bottom of Fuel Filter/Water
Separator10
Windshield Washer Pump BK Bottom of Washer Fluid Reservior 16
Wiper Motor BK Center Rear Engine Compartment 14
BR/BE8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 7
CONNECTOR/GROUND LOCATIONS (Continued)

Splice Number Location Fig.
S123 (V10) Engine Harness, Near T/O to Fuel Injector No. 3 4
S124 (V6, V8) Engine Harness, Top of Transmission 5
S124 (V10) Engine Harness, In T/O to Transmission N/S
S126 (V6, V8) Engine Harness, Near T/O to Fuel Injector No. 1 3
S126 (V10) Engine Harness, Near T/O to Engine Ground 4, 6
S126 (Diesel) Transmission Harness, Near T/O to Powertrain Control Module 2
S127 (V6, V8) Engine Harness, on Top of Transmission 6, 5
S127 (V10) Engine Harness, Near T/O to Transmission 6
S127 (Diesel) Transmission Harness, Near T/O to A/C Low Pressure Switch 2
S128 (Diesel) Transmission Harness, Near T/O to Power Distribution Center 2
S130(V6, V8) Engine Harness, Near T/O to Oil Pressure Sensor 3
S131 (V10) Engine Harness, Rear of Engine 4
S134 Fog Lamp Harness, In T/O to Right Fog Lamp N/S
S136 Fog Lamp Harness, In T/O to Right Fog Lamp N/S
S141 Headlamp and Dash Harness, Near T/O to Joint Connector No. 3 8
S143 Headlamp and Dash Harness, Near T/O to Power Distribution Center 7
S144 Headlamp and Dash Harness, Near T/O to Joint Connector No. 3 8
S160 (Diesel) Engine Harness, Near Fuel Transfer Pump N/S
S161 (Diesel) Transmission Harness, In T/O to Power Distribution Center 2
S164 (Diesel) Engine Harness, Near Fuel Transfer Pump N/S
S165 (Diesel) Engine Harness, Near Engine Control Module N/S
S166 (Diesel) Engine Harness, Near Engine Control Module N/S
S167 (Diesel) Engine Harness, Near Fuel Transfer Pump N/S
S168 (Diesel) Engine Harness, Near T/O to Engine Coolant Temoerature Sensor N/S
S170 (Diesel) Engine Harness, In T/O to Engine Control Module N/S
S171 Transmission Harness, In T/O to Power Distribution Cente 2
S172 (Diesel) Transmission Harness, Near T/O to A/C Low Pressure Switch 2
S173 (Diesel) Transmission Harness, Near T/O to A/C Low Pressure Switch 2
S174 (Diesel) Transmission Harness, In T/O to Power Distribution Center 2
S175 Transmission Harness, In T/O to Power Distribution Center 2
S176 Headlamp and Dash Harness, In Power Distribution Center 7
S177 Headlamp and Dash Harness, In T/O to Daytime Running Lamps Module 7
S179 Transmission Harness, In T/O to Power Distribution Center 2
S180 Headlamp and Dash Harness, Near Intake Air Heater Relay 8
S181 Headlamp and Dash Harness, Near Intake Air Heater Relay 8
S182 Headlamp and Dash Harness, In T/O to Daytime Running Lamps Module 7
S183 Headlamp and Dash Harness, In Power Distribution Center 7
S184 (Diesel) Engine Harnes, in T/O to Engine Control Module N/S
S202 Instrument Panel Harness, Near Overdrive Switch 12
S203 Instrument Panel Harness, Near Overdrive Switch 12
S204 instrument Panel Harness, In T/O to Cup Holder Lamp 12
S207 Instrument Panel Harness, Near Blower Motor 12
S209 Steering Wheel Harness, Near Remote Radio Switch N/S
S210 Steering Wheel Harness, Near Remote Radio Switch N/S
S300 Body Harness, Left Side Instrument Panel 10
8W - 95 - 2 8W-95 SPLICE LOCATIONSBR/BE
SPLICE LOCATIONS (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
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).
ENGINE MISSES ON
ACCELERATION1. Worn or incorrectly gapped spark
plugs1. Replace spark plugs or clean and set
gap. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG -
CLEANING)
2. Spark plug cables defective or
crossed2. Replace or rewire secondary ignition
cables. (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/SPARK PLUG
CABLE - REMOVAL)
3. Dirt in fuel system 3. Clean fuel system
4. Burned, warped or pitted valves 4. Install new valves
5. Faulty coil 5. Test and replace as necessary (Refer
to 8 - ELECTRICAL/IGNITION
CONTROL/IGNITION COIL - REMOVAL)
BR/BEENGINE 3.9L 9 - 5
ENGINE 3.9L (Continued)

DIAGNOSIS AND TESTINGÐCYLINDER
COMPRESSION PRESSURE
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise, the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Clean the spark plug recesses with compressed
air.
(2) Remove the spark plugs (Refer to 8 - ELEC-
TRICAL/IGNITION CONTROL/SPARK PLUG -
REMOVAL).
(3) Secure the throttle in the wide-open position.
(4) Disconnect the ignition coil.
(5) Insert a compression pressure gauge and rotate
the engine with the engine starter motor for three
revolutions.
(6) Record the compression pressure on the third
revolution. Continue the test for the remaining cylin-
ders.
(Refer to 9 - ENGINE - SPECIFICATIONS) for the
correct engine compression pressures.
DIAGNOSIS AND TESTINGÐCYLINDER
COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing)
²Leaks between adjacent cylinders or into water
jacket²Any causes for combustion/compression pressure
loss
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM HOT COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn OFF the
engine.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum and 552 kPa (80 psi) recom-
mended.
Perform the test procedure on each cylinder accord-
ing to the tester manufacturer's instructions. While
testing, listen for pressurized air escaping through
the throttle body, tailpipe or oil filler cap opening.
Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
Refer to CYLINDER COMBUSTION PRESSURE
LEAKAGE DIAGNOSIS CHART below
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
AIR ESCAPES THROUGH
THROTTLE BODYIntake valve bent, burnt, or not
seated properlyInspect valve and valve seat.
Reface or replace, as necessary
AIR ESCAPES THROUGH
TAILPIPEExhaust valve bent, burnt, or not
seated properlyInspect valve and valve seat.
Reface or replace, as necessary
AIR ESCAPES THROUGH
RADIATORHead gasket leaking or cracked
cylinder head or blockRemove cylinder head and inspect.
Replace defective part
MORE THAN 50% LEAKAGE
FROM ADJACENT CYLINDERSHead gasket leaking or crack in
cylinder head or block between
adjacent cylindersRemove cylinder head and inspect.
Replace gasket, head, or block as
necessary
MORE THAN 25% LEAKAGE AND
AIR ESCAPES THROUGH OIL
FILLER CAP OPENING ONLYStuck or broken piston rings;
cracked piston; worn rings and/or
cylinder wallInspect for broken rings or piston.
Measure ring gap and cylinder
diameter, taper and out-of-round.
Replace defective part as necessary
BR/BEENGINE 3.9L 9 - 9
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)