heater DODGE RAM 2001 Service Manual Online

POWERTRAIN CONTROL MODULE C3 (GAS) - BLACK 32 WAY
CAV CIRCUIT FUNCTION
1 C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
2- -
3 K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL
4 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
5 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
6- -
7- -
8 K199 18BR/VT (CALIFORNIA) OXYGEN SENSOR 1/1 HEATER CONTROL
9 K145 20DG/PK (CALIFORNIA) OXYGEN SENSOR DOWNSTREAM RELAY CONTROL
10 K106 18WT/DG LEAK DETECTION PUMP SOLENOID CONTROL
11 V32 18YL/RD SPEED CONTROL SUPPLY
12 A142 14DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
13 T6 18OR/WT (A/T) OVERDRIVE OFF SWITCH SENSE
14 K107 18OR LEAK DETECTION PUMP SWITCH SENSE
15 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
16 K299 18BR.WT OXYGEN SENSOR 2/1 HEATER CONTROL
17 - -
18 - -
19 K31 18BR/WT FUEL PUMP RELAY CONTROL
20 K52 18PK/WT EVAPORATIVE EMISSION SOLENOID CONTROL
21 - -
22 C20 18BR A/C SWITCH SENSE
23 C90 18LG/WT A/C SELECT INPUT
24 V40 18WT/PK BRAKE SWITCH SENSE
25 T125 18DB GENERATOR SOURCE
26 K226 18DB/WT FUEL LEVEL SENSOR SIGNAL
27 D21 18PK/DB SCI TRANSMIT
28 D2 18WT/BK CCD BUS (-)
29 D20 18DG SCI RECEIVE
30 D1 18VT/BR CCD BUS (+)
31 - -
32 V37 18RD/LG SPEED CONTROL SWITCH SIGNAL
RADIO C1 - GRAY 7 WAY
CAV CIRCUIT FUNCTION
1- -
2 X55 18BR/RD LEFT FRONT DOOR SPEAKER (-)
3 X56 18DB/RD RIGHT FRONT DOOR SPEAKER (-)
4 E17 18YL/BK DAY BRIGHTNESS SENSE
5 E2 22OR PANEL LAMPS FEED
6 X12 16RD/WT FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
7 M1 22PK FUSED B(+)
8W - 80 - 70 8W-80 CONNECTOR PIN-OUTSBR/BE

SEAT BELT SWITCH (STANDARD CAB) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 G10 20LG/RD SEAT BELT SWITCH SENSE
2 Z2 20BK/LG GROUND
SEAT HEAT INTERFACE MODULE - 14 WAY
CAV CIRCUIT FUNCTION
1 P7 20LB/BK DRIVER HEATED SEAT SWITCH
2 P144 20BK/WT SEAT TEMPERATURE 5V SUPPLY
3 P130 16TN RIGHT SEAT HEATER B(+) DRIVER
4 F235 16RD B(+) TO HEATED SEAT MODULE
5 P131 16RD/DG LEFT SEAT HEATER B(+) DRIVER
6 F235 16RD B(+) TO HEATED SEAT MODULE
7 P142 22DB RIGHT SEAT TEMPERATURE SENSOR INPUT
8 P141 20TN/LB LEFT SEAT TEMPERATURE SENSOR INPUT
9 P8 20LB/WT PASSENGER HEATED SEAT SWITCH
10 P138 20VT/LG RIGHT SEAT LOW HEAT LED DRIVER
11 P140 20VT/BK RIGHT SEAT HIGH HEAT LED DRIVER
12 P137 20DG LEFT SEAT LOW HEAT LED DRIVER
13 Z2 18BK/LG GROUND
14 P139 20WT LEFT SEAT HIGH HEAT LED DRIVER
SPEED CONTROL SERVO - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 V36 20TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
2 V35 20LG/RD SPEED CONTROL VENT SOLENOID CONTROL
3 V30 20DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT
4 Z1 20BK GROUND
TAILGATE LAMP (DUAL REAR WHEELS) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z13 18BK GROUND
2 L7 18BK/YL HEADLAMP SWITCH OUTPUT
THROTTLE POSITION SENSOR (GAS)-3WAY
CAV CIRCUIT FUNCTION
1 K6 20VT/WT 5V OUTPUT
2 K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL
3 K4 20BK/LB SENSOR GROUND
8W - 80 - 76 8W-80 CONNECTOR PIN-OUTSBR/BE

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.
Cummins Bus (-) Left Front of Engine 10
Cup Holder Lamp Center of Instrument Panel 23,26
Data Link Connector BK Left Bottom of Instrument Panel 23,24
Day/Night Mirror BK Day/Night Mirror N/S
Daytime Running Lamp Module BK Left Fender Side Shield 14
Dome Lamp Rear of Cab 18
Driver Airbag BK Steering Wheel N/S
Driver Door Arm/Disarm Switch BK In Door 19
Driver Door Jamb Switch NAT Door Jamb 19
Driver Door Lock Motor BK In Door 19
Driver Door Window/Lock Switch BL In Door 19
Driver Heated Seat Module BL Under Seat N/S
Driver Heated Seat Switch RD Center of Instrument Panel N/S
Driver Lumbar Motor Under Seat N/S
Driver Power Seat Front Vertical Motor BK Under Seat N/S
Driver Power Seat Horizontal Motor BK Under Seat N/S
Driver Power Seat Rear Vertical Motor Under Seat N/S
Driver Power Seat Switch At Seat N/S
Driver Power Window Motor In Door 19
Duty Cycle EVAP/Purge Solenoid BK Right Fender Side Shield 17
Electric Brake Provision Bottom Left of Instrument Panel N/S
Engine Control Module (Diesel) Left Side Engine 12
Engine Coolant Temperature Sensor (Diesel) BK Left Front of Cylinder Head
(Diesel)10
Engine Coolant Temperature Sensor (Gas) BK On Thermostat Housing 3,6
Engine Oil Pressure Sensor (V6, V8) BK Near Distributor 3
Engine Oil Pressure Sensor (V10) Near Oil Filter 6
Engine Oil Pressure Sensor (Diesel) Left Side of Engine 12
Fuel Heater (Diesel) Left Side of Engine 10
Fuel Injection Pump (Diesel) Left Side of Engine, Below ECM 10
Fuel Injector No.1 BK At Fuel Injector 4,5
Fuel Injector No. 2 BK At Fuel Injector 4,5,6
Fuel Injector No. 3 BK At Fuel Injector 4,5,6
Fuel Injector No. 4 BK At Fuel Injector 4,5,6
Fuel Injector No. 5 BK At Fuel Injector 4,5,6
Fuel Injector No. 6 BK At Fuel Injector 4,5,6
Fuel Injector No. 7 BK At Fuel Injector 4,6
Fuel Injector No. 8 BK At Fuel Injector 4,6
Fuel Injector No. 9 BK At Fuel Injector 6
Fuel Injector No. 10 BK At Fuel Injector 6
Fuel Pump Module LTGY At Frame Rail 22
Fuel Transfer Pump (Diesel) Left Rear of Engine Bottom of
Pump10
BR/BE8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 3
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.
Oxygen Sensor 1/1 Left Bank Up Left Exhaust Manifold Downpipe 13
Oxygen Sensor 1/1 Upstream Catalytic Converter Inlet Side 13
Oxygen Sensor 1/2 Downstream Catalytic Converter Outlet Side 13
Oxygen Sensor 1/2 Left Bank Down Catalytic Converter Outlet Side 13
Oxygen Sensor 1/2 Pre-catalyst Catalytic Converter Inlet Side 13
Oxygen Sensor 1/3 Post Catalyst Catalytic Converter Outlet Side 13
Oxygen Sensor 1/3 Post Catalyst Post Catalyst 13
Oxygen Sensor 2/1 Right Bank Up Right Exhaust Manifold Downpipe 13
Oxygen Sensor 2/2 Right Bank Down Catalytic Converter Outlet Side 13
Park/Neutral Position Switch BK Left Side of Transmission 13
Passenger Airbag At Glove Box 23,26
Passenger Airbag On/Off Switch C1 Lower Right Side of Instrument
Panel23
Passenger Airbag On/Off Switch C2 Lower Right Side of Instrument
Panel23
Passenger Door Arm/Disarm Switch LTGY In Door 19
Passenger Door Jamb Switch NAT In Door 19
Passenger Door Lock Motor BK In Door 19
Passenger Door Window/Lock Switch In Door 19
Passenger Heated Seat Switch BL Center of Instrument Panel N/S
Passenger Heated Seat Module Under Seat N/S
Passenger Lumbar Motor Under Seat N/S
Passenger Power Seat Front Vertical Motor Under Seat N/S
Passenger Power Seat Horizontal Motor Under Seat N/S
Passenger Power Seat Rear Vertical Motor Under Seat N/S
Passenger Power Seat Switch At Seat N/S
Passenger Power Window Motor In Door N/S
Power Seat Heater Control Module Under Seat N/S
Power Mirror Switch Driver Door 19
Power Outlet BK Center of I.P. 25
Powertrain Control Module C1 Right Rear Engine Compartment 1,2
Powertrain Control Module C2 Right Rear Engine Compartment 1,2
Powertrain Control Module C3 Right Rear Engine Compartment 1,2
Radio Choke Relay BK Instrument Panel Center support 23,25
Radio C1 GY Rear of Radio 25
Radio C2 BK Rear of Radio 25
Radio C3 BK Instrument Panel Center support 25
Rear Wheel Speed Sensor BK Left Frame Rail, Near Fuel Tank 21,22
Right Back-Up Lamp BK Rear of Lamp N/S
Right Fog Lamp BK Rear of Fog Lamp N/S
Right Front Door Speaker(Premium BK In Door 19
Right Front Door Speaker(Standard BK In Door 19
Right Front Fender Lamp On Fender 21
8W - 90 - 6 8W-90 CONNECTOR/GROUND LOCATIONSBR/BE
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)

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)

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)