fuel lines DODGE TRUCK 1993 Service Repair Manual

5
- 4
BRAKES

• (3) During road test, make normal and firm brake
stops in 25-40 mph (40-64 Km/h) range. Note faulty
brake operation such as pull, grab, drag, noise, low
pedal, etc.
(4) Inspect suspect brake components and refer to
problem diagnosis information for causes of various
brake conditions.

COMPONENT
INSPECTION
Fluid leak points and dragging brake units can usu­
ally be located without removing any components. The
area around a leak point will be wet with fluid. The
components at a dragging brake unit (wheel, tire, rotor)
will be quite warm or hot to the touch.
Other brake problem conditions will require compo­
nent removal for proper inspection. Raise the vehicle and remove the necessary wheels for better visual ac­

cess.

DIAGNOSING BRAKE
PROBLEMS

PEDAL FALLS
AWAY
A
brake pedal that falls away under steady foot
pressure is the result of a system leak. The leak
point could be at a brakeline, fitting, hose, or caliper. Internal leakage in the master cylinder caused by
worn or damaged piston cups, may also be the prob­ lem cause.
If leakage is severe, fluid will be evident at or around
the leaking component. However, internal leakage in
the master cylinder may not be physically evident. Re­ fer to the cylinder test procedure in this section.

LOW PEDAL
If a low pedal is experienced, pump the pedal sev­
eral times. If the pedal comes back up, worn lining
and worn rotors or drums are the likely causes.
A decrease in fluid level in the master cylinder res­
ervoirs may only be the result of normal lining wear.
Fluid level can be expected to decrease in proportion to wear. It is a result of the outward movement of
caliper and wheel cylinder pistons to compensate for
normal wear. Top off the reservoir fluid level and
check brake operation to verify proper brake action.
SPONGY PEDAL. A spongy pedal is most often caused by air in the sys­
tem. Thin brake drums or substandard brake lines and
hoses can also cause a spongy pedal. The proper course
of action is to bleed the system and replace thin drums and suspect quality brake lines and hoses.

HARD PEDAL
OR
HIGH
PEDAL
EFFORT
A hard pedal or high pedal effort may be due to
lining that is water soaked, contaminated, glazed, or
badly worn. The power booster or check valve could also be faulty. On diesel engine models, high pedal effort may be
the result of a low vacuum condition. If the booster and check valve are OK, the problem may be related
to a vacuum pump hose, hose connection, hose fit­
ting, pump diaphragm, or drive gear. Vacuum pump output can be checked with a standard vacuum
gauge. Vacuum output should range from 8.5 to 25 inches vacuum. If vacuum pump output is within

limits,
check the power booster and check valve as
described in this section.

BRAKE DRAG
Brake drag occurs when the lining is in constant
contact with the rotor or drum. Drag can occur at
one wheel, all wheels, fronts only, or rears only. It is a product of incomplete brakeshoe release. Drag can
be minor or severe enough to overheat the linings,
rotors and drums.
Brake drag can also effect fuel economy. If undetec­
ted, minor brake drag can be misdiagnosed as an en­ gine or transmission/torque converter problem.
Minor drag will usually cause slight surface charring
of the lining. It can also generate hard spots in rotors and drums from the overheat-cool down process. In most

cases,
the rotors, drums, wheels and tires are quite
warm to the touch after the vehicle is stopped.
Severe drag can char the brake lining all the way
through. It can also distort and score rotors and drums to the point of replacement. The wheels, tires and brake components will be extremely hot. In se­
vere cases, the lining may generate smoke as it chars
from overheating.
Some common causes of brake drag are:
• seized or improperly adjusted parking brake cables
• loose/worn wheel bearing
• seized caliper or wheel cylinder piston
• caliper binding on corroded bushings or rusted
slide surfaces
• loose caliper mounting bracket
• drum brakeshoes binding on worn or damaged sup­
port plates
• misassembled components. If brake drag occurs at all wheels, the problem may
be related to a blocked master cylinder return port, or faulty power booster that binds and does not release.

BRAKE FADE
Brake fade is a product of overheating caused by
brake drag. However, brake overheating and subse­ quent fade can also be caused by riding the brake
pedal, making repeated high deceleration stops in a short time span, or constant braking on steep moun­
tain roads. Refer to the Brake Drag information in
this section for additional causes.

PEDAL
PULSA
TION
Pedal pulsation is caused by components that are
loose, out of round, or worn beyond tolerance limits.

7 - 20
COOLING
SYSTEM

•

HOSE
CLAMP
HOSE

J9207-36
Fig.
16
Hose
Clamp
Tool
WITH AIR
CONDITIONING
(A/C)

REMOVAL
If equipped with A/C, the generator and A/C com­
pressor along with their common mounting bracket (Fig. 17) must be partially removed. Removing the
generator or A/C compressor from their mounting
bracket is not necessary. Also, discharging the A/C system is not necessary. Do not remove any refrig­
erant lines from A/C compressor.

SUPPORT BRACKET (ROD)
GENERATOR/COMPRESSOR
MOUNTING
BRACKET

J9307-66

Fig.
17 Generator—A/C
Compressor
Mounting
Bracket—
Typical

WARNING;
THE A/C
SYSTEM
IS
UNDER
PRESSURE
EVEN
WITH
THE
ENGINE OFF. REFER
TO
REFRIG­

ERANT
WARNINGS
IN
GROUP
24,
HEATING
AND

AIR
CONDITIONING.

(1) Disconnect negative battery cable from battery. (2) Partially drain cooling system. Refer to Drain­
ing Cooling System in this group.
Do not waste reusable coolant. If the solution is
clean, drain the coolant into a clean container for re­
use.

(3) Remove upper radiator hose clamp at radiator.
Special Clamp Tool number 6094 (Fig. 16) may be
used to remove the constant tension clamps. Remove
hose at radiator.
(4) Disconnect throttle cable from clip at radiator
fan shroud. (5) Unplug wiring harness from A/C compressor.
(6) Remove the air cleaner assembly.
(7) Remove accessory drive belt. Refer to Belt Re­
moval/Installation in the Engine Accessory Drive
Belt section of this group.
(8) 3.9L/5.2L/5.9L LDC-Gas: The drive belt idler
pulley must be removed to gain access to one of the
A/C compressor/generator bracket mounting bolts. Remove the idler pulley bolt and remove idler pulley (Fig. 18).

GENERATOR/COMPRESSOR
AND
BRACKET

SUPPORT BRACKET

IGNITION

COIL
BRACKET
Fig.
18 Idler Pulley-3.9U5.2U5.9L
LDC-Gas
Engine
5.9L HDC-Gas: The automatic belt tensioner/pul-
ley assembly must be removed to gain access to one
of the A/C compressor/generator bracket mounting

bolts.
Remove the tensioner mounting bolt (Fig. 19) and remove tensioner.
(9) Remove the engine oil dipstick tube mounting
bolt at the side of the A/C-generator mounting
bracket.
(10) Disconnect throttle body control cables. Refer
to Accelerator Pedal and Throttle Cable in Group 14,
Fuel System.

•

ENGINES
9 - 9 SERVICE DIAGNOSIS (DIESEL ENGINE) • PERFORMANCE (CONT.)

CONDITION
POSSIBLE
CAUSES
CORRECTION

ENGINE
HARD
TO

START,
OR
WILL

NOT
START—SMOKE

FROM
EXHAUST

(Cont'd)
Fuel pump Inoperative.
Injection pump
throttle
linkage

loose
or
damaged.

Contaminated
fuel.

Worn
or inoperative injection
pump.

Injection pump out of time.

Valves
incorrectly adjusted.

One
or more injectors worn or not operating properly.
Disconnect
fuel
line and verify
fuel
delivery. If needed replace

pump.

Visually
check the linkage. Tighten/replace linkage.
Verify by operating the engine with clean
fuel
from a temporary tank. Check for presence of
gasoline.
Drain and

flush
fuel
supply tanks.
Replace
fuel/water separator
filter.

Visually
check
fuel
delivery with an externally connected injector to one of the pump outlets. Replace the pump if
fuel
is
not being delivered.

Check/time
the pump
(refer
to Group 14, Fuel
System).

Adjust
valves.
Check/replace
bad improperly operating injectors.

ENGINE
STARTS,

BUT
WILL
NOT

KEEP
RUNNING
Idle speed too low for the

accessories.

Intake air or exhaust
system

restricted.

Air
in the
fuel
system
or the

fuel
supply is inadequate.
Fuel waxing due to extremely

cold
weather.

Contaminated
fuel.
Adjust
the idle
speed.

Visually
check for exhaust restriction and inspect the air intake.
Repair/replace restricting parts.

Check
the flow through the
filter
and bleed the
system.
Locate

and
eliminate the air source.
Verify by inspecting the
fuel
filter.
Clean the
system
and use
climatized fuel. Replace fuel/water separator
filter.
Check
fuel

heater for proper operation.
Verify by operating the engine with clean
fuel
from a temporary

supply
tank. Check for presence of
gasoline.
Replace fuel/water

separator
filter.

SURGING
(SPEED

CHANGE)
If the condition
occurs
at idle,
the idle speed is set too low for
the
accessories.

High
pressure
fuel
leak.

One
or more injectors worn or not operating properly.
Improperly operating injection

pump.
Adjust
the idle.

Inspect/correct
leaks in the high pressure lines. Fittings and
delivery valve
sealing
washers.

Check/replace
the inoperative injectors.

Replace
the injection pump.

ROUGH
IDLE

(IRREGULARLY
FIRING

OR
ENGINE
SHAKING)
Cold
engine.
Idle speed too low for the

accessories.

Engine
mounts
damaged
or
loose.
Refer to troubleshooting
logic
for intake manifold heater
system

(see
Group 11,
Exhaust
System
& Intake Manifold)

Adjust
idle
speed.

Repair
or replace mounts. J9109-233

9
- 10
ENGINES
— _
•
CONDITION

possmu
CLOSES
CORRECTION

ROUGH
IDLE

(IRREGULARLY
FIRING

OR
ENGINE
SHAKING)
(Cont'd)
High
pressure
fuel
leaks.

Air In the
fuel
system.
Correct leaks in the high pressure lines, fittings or
delivery

valves.

Bleed the
fuel
system and
eliminate
the source of the air.

Sticking
needle
valve
in an
injector.
Check and replace the
injector
with
the sticking
needle
valve.

ENGINE
RUNS
ROUGH

OR
MISFIRING
Fuel
injection
lines
leaking.

Correct leaks in the high pressure lines, fittings,
injector
sealing

washers
or
delivery
valves.
Air in the
fuel
or the
fuel
supply
is
inadequate.
Check the flow through the
filter
and bleed the system. Locate
and
eliminate
the air source.

Contaminated
fuel.
Verify
by operating the engine
with
clean
fuel
from a temporary

supply
tank. Check for presence of gasoline. Replace
fuel/water

separator
filter.

Incorrect
valve
adjustment.
Check for a
bent
push rod and adjust valves. Replace push rod,
if necessary.

Injection
pump
timing
incorrect.
Check/time pump
(refer
to Group 14,
Fuel
System).

Improperly
operating
injectors.
Replace inoperative injectors.
Defective
injection
pump

(delivery
valves).
Replace
injection
pump.

Camshaft
out of
time.
Check/correct gear
train
timing alignment.

Damaged
camshaft or
tappets.
Inspect camshaft valve
lift.
Replace camshaft and tappets.

ENGINE
RPM WILL NOT

REACH
RATED
SPEED
Engine
overloaded.

Verify
high
idle
speed
without
load. Investigate operation to be
sure correct gear is being used.

Improperly
operating
tachometer.
Verify
engine speed
with
hand tachometer—correct as required.

Throttle
linkage
worn
or
incorrectly
adjusted.
Adjust linkage for stop-to-stop
fuel
control
lever
travel.
Replace
linkage if necessary.
Partially
engaged
mechanical

shutdown
lever.
Adjust and place shutdown
lever
in the run position.

Inadequate
fuel
supply. Check the
fuel
flow through the system to locate the reason for
inadequate
fuel
supply—correct as required.

Improperly
operating
injection

pump.
Replace
injection
pump.

LOW
POWER
Fuel
control
lever
not
moving
to

full
throttle.
Check/correct for stop-to-stop
travel.

Mechanical/shutdown
lever
partially
engaged.
Check to see if the shutdown
lever
is in run position.

High
oil
level.
Check/correct oil level.

Engine
overloaded.
Check for added loading from accessories or driven units, brakes

dragging
and
other
changes in vehicle loading. Repair/replace as
needed.
J9109-264
SERVICE
DIAGNOSIS (DIESEL ENGINE)
•
PERFORMANCE (CONT.)

•

ENGINES
9 - 11 SERVICE DIAGNOSIS (DIESEL ENGINE) - PERFORMANCE (CONT.)

CONDITION
POSSIBLE
CAUSES
CORRECTION

LOW
POWER
(Cont'd)
SJow
throttle
response, leaking
air
fuel
control
tube
or
improperly
operating
control

in the pump. Tighten the fittings. Replace the pump if the controls are not
functioning.
Incorrect
external
injection

pump
timing. Verify
that
injection pump timing marks are aligned (see Group
14, Fuel System).
Inadequate intake air flow. Inspect/replace air cleaner element. Look for other restrictions.

High
pressure
fuel
leak. Inspect/correct leaks in the high pressure lines, fittings
injector

sealing
washers or delivery valve
seals.

Inadequate
fuel
supply.
Check
the flow through the
filter
to locate the source of the
restriction.

High
fuel
temperature. Verify
that
fuel
heater is off during warm weather. Check for a
restricted
fuel
drain manifold. Repair/replace as needed.

Poor
quality
fuel
or
fuel

contaminated
with
gasoline. Verify by operating from a temporary tank
with
good
fuel.

Check
for presence of
gasoline.
Replace
fuel/water
separator

filter.

Air
leak between the turbo- charger and the intake manifold. Check/correct leaks in the air crossover tube,
hoses,
gaskets,

and
around mounting capscrews or through holes in the manifold
cover.

Exhaust
leak at the manifold
or turbocharger. Check/correct leaks in the manifold or turbocharger
gaskets.

If manifold is cracked, replace manifold.
Improperly operating turbo-
charger. Inspect/replace turbocharger.
Valve clearance incorrect.
Check/adjust
valves.
Injection pump improperly
operating. Check/time pump
(refer
to Group 14, Fuel System).

Worn
or improperly operating injectors. Check/replace injectors.
Improperly operating injection

pump.
Replace
injection pump.

Excessive
exhaust restriction. Check/correct the restriction in the exhaust system.

EXCESSIVE
EXHAUST

SMOKE
Engine
running too cold
(white

smoke).
Refer to troubleshooting logic for coolant
temperature
below
normal
(refer
to Group 7,
Cooling
System).
Inspect intake
manifold heater/KSB valve for proper operation.
Inadequate intake air.
Inspect/change
air cleaner. Look for other restriction.

Air
leak between turbocharger

and
intake manifold. Check/correct leaks in the air crossover tube,
hoses,
gaskets,

mounting capscrews or through holes in the manifold cover.

Exhaust
leak at the manifold
or turbocharger. Check/correct leaks in the manifold or turbocharger
gaskets.

If cracked replace manifold.
Improperly operating
turbocharger. Inspect/replace turbocharger.
J9209-57

TRANSFER

CASE

INSULATOR

MOUNTING PLATE

NUT(B
RAIL

ASSEMBLY
SPACER

UPPER

INSULATOR

NUT®
LOWER

INSULATOR

J9109-242
Fig.
9 Rear
Engine
Support—4WD
with
Manual

Transmission
(8) If necessary, remove the transmission support
spacer (automatic transmission) from the extension
assembly (Fig. 8).
(9) If necessary, remove the engine rear support
plate (automatic transmission) from the transfer case (Fig. 8).

INSTALLATION-4WD
(1) If removed, position the engine rear support
plate (automatic transmission) to the transfer case (Fig. 8). Install the bolts and tighten to 41 N-m (30
ft. lbs.) torque.
(2) If removed, position the transmission support
spacer (automatic transmission) to the extension as­
sembly (Fig. 8). Install the bolts and tighten to 68 N-m (50 ft. lbs.) torque.
(3) Install insulator mounting plate, mounting

bolts,
spacers, washers and upper/lower insulators to
the rail assembly (Figs. 8 and 9). Tighten the mount­
ing nuts to 204 N*m (150 ft. lbs.) torque.
(4) AUTOMATIC TRANSMISSION-Align the
engine rear support plate and the transmission sup­
port spacer to the insulator mounting plate (Fig. 8). Lower the engine and transmission onto the insula­
tor mounting plate and install the bolts. Tighten the transmission support spacer nuts to 204 N-m (150 ft. lbs.) torque. Tighten the engine rear support plate
bolts to 41 N-m (30 ft. lbs.) torque.
(5) MANUAL TRANSMISSION—Align the
transfer case to the insulator mounting plate and lower the engine and transmission. Install the bolts and tighten the nuts (Fig. 9 - nut A) to 204 N-m (150 ft. lbs.) torque. Install the bolts and tighten the nuts
(Fig. 9 - nut B) to 41 N-m (30 ft. lbs.) torque. (6) Install the skid plate.
(7) Lower the vehicle.

ENGINE
ASSEMBLY

REMOVAL (1) Scribe hood hinge outlines on hood. Remove the
hood.
(2) Remove the battery. (3) Drain cooling system (refer to Group 7, Cooling
System for the proper procedure).
(4) Remove the air cleaner. (5) Disconnect the radiator and heater hoses. Re­
move radiator (refer to Group 7, Cooling System).
(6) Set fan shroud aside. (7) Remove the vacuum lines. (8) Remove the distributor cap and wiring.
(9) Disconnect the accelerator linkage.
(10) Remove MPI throttle body. (11) Disconnect the fuel lines. (12) Disconnect the starter wires.
(13) Disconnect the oil pressure wire. (14) Discharge the air conditioning system, if
equipped (refer to Group 24, Heating and Air Condi­
tioning for service procedures). (15) Disconnect the air conditioning hoses.
(16) Disconnect the power steering hoses, if
equipped. (17) Remove starter motor (refer to Group 8B, Bat­
tery/Starter/Generator Service). (18) Remove the generator (refer to Group 8B, Bat­
tery/Starter/Generator Service).
(19) Raise and support the vehicle on a hoist.
(20) Disconnect exhaust pipe at manifold.
(21) AUTOMATIC TRANSMISSION: (a) Support transmission. This will assure that
the torque converter will remain in proper position in the transmission housing. (b) Remove bell housing bolts and inspection
plate.
(c) Attach a C-clamp on front bottom of trans­
mission torque converter housing to prevent torque
converter from falling out.
(d) Remove torque converter drive plate bolts
from torque converter drive plate. Mark converter and drive plate to aid in assembly.
(22) MANUAL TRANSMISSION: (a) Support transmission.
(b) Disconnect clutch release mechanism and re­
move transmission to clutch housing bolts.

CAUTION:
DO NOT
lift
the engine by the intake
manifold.

(23) Install an engine lifting fixture.
(24) Remove engine front mount bolts.

•
3.9L
ENGINE
9 - 21 (25) Lower the vehicle.
(26) On automatic transmission vehicles, discon­
nect the engine from the torque converter drive
plate. On manual transmission vehicles, move engine forward until drive pinion shaft clears the clutch

disc.
Remove engine from engine compartment. (27) Install engine assembly on engine repair
stand.
INSTALLATION (1) Remove engine from the repair stand and posi­
tion in the engine compartment.
(2) Install engine support fixture.
(3) Raise and support the vehicle on a hoist.

(4)
AUTOMATIC TRANSMISSION: (a) Position the torque converter and drive plate.
Install torque converter drive plate bolts. Tighten
the bolts to 31 Nnn (270 in. lbs.) torque.
(b) Install the engine front mounts.
(c) Install bell housing bolts. Tighten the bolts to
41 N-m (30 ft. lbs.) torque.
(d) Remove C-clamp.
(e) Install the inspection plate.
(5) MANUAL TRANSMISSION: (a) Position the drive pinion shaft to the clutch

disc.
(b) Connect the clutch release mechanism and
install the transmission to clutch bolts. Tighten the
bolts to 68 N-m (50 ft. lbs.) torque.
(c) Install the engine front mounts.
(6) Remove transmission support.
(7) Install exhaust pipe to manifold.
(8) Lower the vehicle.
(9) Remove engine lifting fixture.
(10) Install the generator (refer to Group 8B, Bat­
tery/Starter/Generator Service). (11) Install starter motor (refer to Group 8B, Bat­
tery/Starter/Generator Service). (12) Connect power steering hoses, if equipped.
(13) Connect air conditioning hoses.
(14) Evacuate and charge the air conditioning sys­
tem, if equipped (refer to Group 24, Heater and Air Conditioning for service procedures). (15) Using a new gasket, install MPI throttle body.
Tighten the throttle body bolts to 23 N-m (200 in. lbs.) torque. (16) Connect the accelerator linkage.
(17) Connect the starter wires. (18) Connect the oil pressure wire.
(19) Install the distributor cap and wiring.
(20) Connect the vacuum lines.
(21) Connect the fuel lines.
(22) Install the radiator (refer to Group 7, Cooling
System). Connect the radiator hoses and heater

hoses.

(23) Install fan shroud in position. (24) Fill cooling system (refer to Group 7, Cooling
System for the proper procedures). (25) Install the air cleaner.
(26) Install the battery.
(27) Warm engine and adjust.
(28) Install hood and line up with the scribe
marks. (29) Road test vehicle.

CYLINDER
HEAD COVER
A steel backed silicon gasket is used with the cyl­
inder head cover (Fig. 1). This gasket can be used again.

CYLINDER HEAD COVER GASKET

J9209-104

Fig.
1 Cylinder Head
Cover
Gasket

REMOVAL (1) Disconnect the negative cable from the battery.
(2) Disconnect closed ventilation system and evap­
oration control system from cylinder head cover. (3) Remove cylinder head cover and gasket. The
gasket may be used again.
CLEANING Clean cylinder head cover gasket surface. Clean head rail, if necessary.
INSPECTION Inspect cover for distortion and straighten, if nec­
essary. Check the gasket for use in "head cover installation.
If damaged, use a new gasket.
INSTALLATION (1) The cylinder head cover gasket can be used
again. Install the gasket onto the head rail.
(2) Position the cylinder head cover onto the gas­
ket. Tighten the bolts to 11 N-m (95 in. lbs.) torque. (3) Install closed crankcase ventilation system and
evaporation control system.
(4) Connect the negative cable to the battery.

ROCKER
ARMS

REMOVAL (1) Disconnect spark plug wires by pulling on the
boot straight out in line with plug.
(2) Remove cylinder head cover and gasket.

(3) Remove the rocker arm bolts and pivots (Fig.

2).
Place them on a bench in the same order as re­
moved.
(4) Remove the push rods and place them on a
bench in the same order as removed.

ROCKER
ARMS

J9209-66
Fig.
2
Rocker Arms
INSTALLATION
(1) Rotate the crankshaft until the "V6" mark
lines up with the TDC mark on the timing chain
case cover. This mark is located 147° ATDC from the
No.l firing position.

CAUTION:
DO NOT
rotate
or
crank
the
engine dur­
ing
or
immediately
after
rocker
arm
installation.
Al­

low
the
hydraulic roller tappets adequate time
to
bleed down (about
5
minutes).

(2) Install the push rods in the same order as re­
moved.
(3) Install rocker arm and pivot assemblies in the
same order as removed. Tighten the rocker arm bolts
to 28 N*m (21 ft. lbs.) torque.
(4) Install cylinder head cover.
(5) Connect spark plug wires.

CYLINDER
HEADS
The alloy cast iron cylinder heads (Fig. 3) are held
in place by 8 bolts. The spark plugs are located in
the peak of the wedge between the valves.

REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain cooling system (refer to Group 7, Cooling
System for the proper procedures). (3) Remove the heat shields (Fig. 4).
SPARK SPARK
INTAKE

PLUGS
PLUG VALVE
EXHAUST INTAKE EXHAUST VALVE VALVES VALVES
J9309-35

Fig.
3 Cylinder Head
Assembly Fig.
4
Exhaust
Manifold Heat
Shields

(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) Remove the air cleaner.
(8) Disconnect the fuel lines.
(9) Disconnect accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables. (10) Remove the return spring.
(11) Remove distributor cap and wires.
(12) Disconnect the coil wires.
(13) Disconnect heat indicator sending unit wire.
(14) Disconnect heater hoses and bypass hose.
(15) Remove cylinder head covers and gaskets.
(16) Remove intake manifold and throttle body as
an assembly. Discard the flange side gaskets and the
front and rear cross-over gaskets.
(17) Remove exhaust manifolds.
(18) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations.

(9) Install the flange gaskets. Be sure 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. 8). The words MANIFOLD SIDE should be
visible on the center of each flange gasket.
FLANGE GASKET


INTAKE
AAANIFOLD
CYLINDER
HEAD GASKET
J9209-101

Fig.
8 Intake Manifold Flange
Gasket
Alignment

(10) Carefully lower intake manifold into position
on the cylinder block and cylinder heads. Use the alignment dowels in the cross-over gaskets to posi­
tion the intake manifold. After intake manifold is in
place, inspect to make sure seals are in place.
(11) The following torque sequence duplicates the
expected results of the automated assembly system
(Fig. 9).
• Step
1-Tighten
bolts 1 and 2 to 8 N-m (72 in. lbs.)
torque. Tighten in alternating steps 1.4 N-m (12 in. lbs.) torque at a time.
• Step 2—Tighten bolts 3 through 12, in sequence,
to 8 N-m (72 in. lbs.) torque.
• Step 3—Check that all bolts are tighten to 8 N-m (72 in. lbs.) torque.
• Step 4—Tighten all bolts, in sequence, to 16 N-m (12 ft. lbs.) torque.
• Step 5—Check that all bolts are tighten to 16 N-m (12 ft. lbs.) torque. (12) Install exhaust manifolds. Tighten the bolts
and nuts to 34 N-m (25 ft. lbs.) torque.
FRONT OF ENGINE

J9209-59

Fig.
9 Intake Manifold
Bolt
Tightening
Sequence
(13) Adjust spark plugs to specifications (refer to
Group 8D, Ignition System). Install the plugs and
tighten to 41 N-m (30 ft. lbs.) torque.
(14) Install coil wires. (15) Connect heat indicator sending unit wire.
(16) Connect the heater hoses and bypass hose.
(17) Install distributor cap and wires.
(18) Hook up the return spring.
(19) Connect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(20) Install the fuel lines.
(21) Install the generator and drive belt. Tighten
generator mounting bolt to 41 N-m (30 ft. lbs.)
torque. Tighten the adjusting strap bolt to 23 N-m (200 in. lbs.) torque. Refer to Group 7, Cooling Sys­
tem for adjusting the belt tension. (22) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts. (23) Place the cylinder head cover gaskets in posi­
tion and install cylinder head covers. Tighten the
bolts to 11 N-m (95 in. lbs.) torque.
(24) Install closed crankcase ventilation system.
(25) Connect the evaporation control system.
(26) Install the air cleaner.
(27) Install the heat shields. Tighten the bolts to
41 N-m (30 ft. lbs.) torque. (28) Fill cooling system (refer to Group 7, Cooling
System for proper procedure). (29) Connect the negative cable to the battery.

•
3.9L
ENGINE
I - 21
VIBRATION
DAMPER

REMOVAL
(1) Disconnect the negative cable from the battery,
(2) Remove fan shroud retainer bolts and set
shroud back over engine.
(3) Remove the cooling system fan.
(4) Remove the serpentine belt (refer to Group 7,
Cooling System).
(5) Remove the vibration damper pulley.
(6) Remove vibration damper bolt and washer from
end of crankshaft.
(7) Install bar and screw from Puller Tool Set

C-3688.
Install 2 bolts with washers through the
puller tool and into the vibration damper (Fig. 1).
(8) Pull vibration damper off of the crankshaft.
J9209-81

Fig. 1 Vibration
Damper
Assembly INSTALLATION

(1) Position the vibration damper onto the crank­
shaft.
(2) Place installing tool, part of Puller Tool Set
C-3688 in position and press the vibration damper
onto the crankshaft (Fig. 2).
Fig. 2 Installing Vibration Damper
(3) Install the crankshaft bolt and washer. Tighten
the bolt to 183 N*m (135 ft. lbs.) torque.
(4) Install the crankshaft pulley. Tighten the pul­
ley bolts to 23 N*m (200 in. lbs.) torque.
(5) Install the serpentine belt (refer to Group 7,
Cooling System).
(6) Install the cooling system fan. Tighten the
bolts to 23 N*m (17 ft. lbs.) torque. (7) Position the fan shroud and install the bolts.
Tighten the retainer bolts to 11 N*m (95 in. lbs.)
torque.
(3)
Connect the negative cable to the battery.

TIMING CHAIN
COVER
REMOVAL (1)
Disconnect the negative cable from the battery.

(2)
Drain cooling system (refer to Group 7, Cooling
System).

(3)
Remove the serpentine belt (refer to Group 7,
Cooling System).
(4)
Remove water pump (refer to Group 7, Cooling
System).
(5)
Remove power steering pump (refer to Group

19,
Steering).

(6)
Remove vibration damper. (7) Remove fuel lines (refer to Group 14, Fuel Sys­

tem).

(8) Loosen oil pan bolts and remove the front bolt
at each side.
(9)
Remove the cover bolts.

(10)
Remove chain case cover and gasket using ex­
treme caution to avoid damaging oil pan gasket.

(11)
Place a suitable tool behind the lips of the oil
seal to pry the oil seal outward. Be careful not to
damage the crankshaft seal surface of cover (Fig. 3). Fig. 3 Removal of Front Crankshaft Oil Seal
TIMING CHAIN STRETCH
(1) Place a scale next to the timing chain so that
any movement of the chain may be measured.

(2)
Place a torque wrench and socket over cam­
shaft sprocket attaching bolt. Apply torque in the di­
rection of crankshaft rotation to take up slack; 41
N#m (30 ft. lbs.) torque with cylinder head installed or 20 N»m (15 ft. lbs.) torque with cylinder head re­
moved. With a torque applied to the camshaft sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block the crankshaft to
prevent rotation.

(3)
Hold a scale with dimensional reading even
with the edge of a chain link. With cylinder heads installed, apply 14 N*m (30 ft. lbs.) torque in the re­
verse direction. With the cylinder heads removed, ap-