fuel rail DODGE TRUCK 1993 Service Repair Manual

•
• —
LUiRICATlON
AND
MAINTENANCE
0 - 1
CONTENTS

page
page

CHASSIS
AND
BODY
28
ENGINE MAINTENANCE
14
DRIVETRAIN
.,,, 22
GENERAL INFORMATION
1

GENERAL
INFORMATION INDEl

page

Classification
of
Lubricants
. 3

Components
Requiring
No
Lubrication
4

Fuel Requirements
. 2
Introduction
1

Lubrication
and
Replacement Parts Recommendation
3
page

Routine Maintenance
2

Starting
Assistance (Jump Starting)
9

Vehicle
Lifting
Recommendations
............ 10

Vehicle Noise
Control
2

Vehicle Towing Recommendations
11

INTRODUCTION
Lubrication and maintenance is divided into re­
quired and recommended service tasks. The required service tasks must be completed to verify the emis­
sion controls function correctly. The recommended
service tasks should be completed to maintain safety
and durability. This information will assist the service personnel
in providing maximum protection for each owner's
vehicle. Conditions can vary with individual driving habits.
It is necessary to schedule maintenance as a time in­
terval as well as a distance interval. It is the owner's responsibility to determine the ap­
plicable driving condition. Also to have the vehicle serviced according to the maintenance schedule, and
to pay for the necessary parts and labor. Vehicles with a Gross Vehicle Weight Rating
(GVWR) of 3 855 kg (8,500 lbs.) or less must conform
to light duty emission standards. Vehicles with a Gross Vehicle Weight Rating (GVWR) of 3 856 kg
(8,501 lbs.) or more must conform to heavy duty
emission standards. The GVWR for each vehicle is listed on the Safety
Certification Label. This label is affixed to the driver
side door pillar (Fig. 1).
Additional maintenance and lubrication informa­
tion is listed in the Owner's Manual.
Mm
rv
CHRYSLER
DATE
OF MFR
MFD BY CORPORATION
GVWR
GAWR FRONT
GAWR REAR
WITH
TIRES

WITH
TIRES
RIMS
AT

RIMS
AT

PSI
COLD

PSI
COLD THIS VEHICLE CONFORMS
TO
ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY

STANDARDS
IN
EFFECT ON
THE
DATE
OF
MANUFACTURE SHOWN ABOVE.

SINGLE
DUAL

BAR
CODE

VEHICLE MADE
IN

4648503
J9UN-25

Fig. 1 Vehicle Safety
Certification
Label

SEVERE DRIVING
CONDITIONS
Vehicles subjected to severe driving conditions
should decrease the interval between component
maintenance. Severe driving conditions are defined
as:

• Frequent short trip driving less than 24 km (15
miles)
• Frequent driving in dusty conditions
• Trailer towing
• Extensive engine idling
• Sustained high speed operation
• Desert operation
• Frequent starting and stopping
• Cold climate operation

LUBRICATION
AND
MAINTENANCE

LUBRICATION
AND
MAINTENANCE
0-11

J
DRIVE-ON
HOIST

I
FRAME
CONTACT
HOIST
TWIN
POST
CHASSIS
HOIST

FLOOR
JACK
RROOD30
Fig.
8 Correct Vehicle Lifting
Locations
An axle tube
A body side sill
A steering linkage component
A drive shaft
The engine or transmission oil pan
The fuel tank
• A front suspension arm Use the correct frame rail lifting locations only
(Fig. 8).
HOIST A vehicle can be lifted with:
• A single-post, frame-contact hoist
• A twin-post, chassis hoist
• A ramp-type, drive-on hoist
When a frame-contact type hoist is used, verify
that the lifting pads are positioned properly (Fig. 8).

WARNING:
WHEN
A
SERVICE
PROCEDURE
RE­
QUIRES
THE
REMOVAL
OF
THE
REAR
AXLE,
FUEL

TANK,
OR
SPARE
TIRE,
EITHER:

• PLACE ADDITIONAL WEIGHT ON THE REAR
END OF THE VEHICLE
« ATTACH THE VEHICLE TO THE HOIST
« PLACE JACK STANDS UNDER THE VEHICLE
FOR SUPPORT TO PREVENT TIPPING WHEN
THE CENTER OF BALANCE CHANGES
4WD VEHICLES A standard hoist can be used to lift a 4WD vehicle.
The hoist should be inspected for adequate clearance. The lift arms, pads or ramps should be adjusted to
ensure that there is adequate clearance (Fig. 9).
ADJUSTMENT
PAD

ii 7
MAINTAIN
CLEARANCE
HOIST
ARM

RK44

Fig.
9 Lifting 4WD Vehicle
With
Single-Post
Hoist—
Typical
When a twin-post hoist is used, a 4 x 4 x 12-inch
wood spacer also could be required. Place the wood spacer under the front axle (opposite the differential
housing). This will maintain balance and level lift­ ing.

CAUTION:
The
block
that
is
used must
be
secured in
a
safe manner. This
will
ensure
that
it
will
not un­

balance
the
vehicle.
VEHICLE
TOWING
RECOMMENDATIONS
When it is necessary to tow a Ram Truck, the rec­
ommended method is either:
• the sling-type, rear-end raised towing method; or
• the wheel-lift towing method with a tow dolly lo­
cated under the front wheels. A vehicle with flat-bed hauling equipment can also
be used to transport a disabled vehicle.

SLING-TYPE
FLAT
BED
RR0OD29
Fig.
10 Tow Vehicles
With
Approved
Equipment

0 - 12
LUBRICATION
AND
MAINTENANCE

• A vehicle equipped with SAE approved sling-type
towing equipment can be used (Fig. 10). However,
many vehicles are equipped with air dams, spoilers, and/or ground effect panels. In this case a wheel-lift
towing vehicle or a flat-bed hauling vehicle is recom­ mended (Fig. 10). If a flat bed device is used, the ap­
proach angle should not exceed 15 degrees.
GROUND CLEARANCE The lifted wheels of the disabled vehicle should be
a minimum of 10 cm (4 in.) off the ground. Make
sure there is enough clearance at the opposite end.
This is critical when towing over rough terrain. If necessary, the rear ground clearance can be in­creased by removing the wheels from the lifted end
and then towing with the lifted end closer to the
ground. If the rear wheels are removed, secure the
brake drums. A 20 cm (8 in.) ground clearance must
be maintained between brake drums or rotors and the ground.
SAFETY PRECAUTIONS The following safety precautions must be consid­
ered when preparing for and during a vehicle towing operation:
• Remove exhaust pipe tips that interfere with the
tow sling and crossbar • Padding should be placed between the tow sling/
crossbar and any painted surfaces
• If the vehicle is damaged, secure the loose and pro­
truding parts
• Always use a safety chain system that is indepen­ dent of the lifting and towing equipment
• When placing tow hooks on the rear axle, position them so they do not damage the brake tubing or
hoses
• Do not allow any of the towing equipment to con­
tact the fuel tank
• Do not tow the vehicle by connecting to the front
or rear shock absorbers
• The operator should not go under a vehicle while
it is lifted by the towing equipment. The vehicle
should first be supported by safety stands
• Do not allow passengers in a vehicle being towed
• Observe all state and local laws involving warning signals, night illumination, speed, etc.
• Do not exceed a towing speed of 48 km/h (30 mph)
• Avoid towing distances of more than 24 km (15
miles) whenever possible • Do not attach tow chains or a tow sling to a
bumper, the steering linkage, the universal joints, or a drive shaft
REAR-END RAISED TOWING It is recommended that the rear-end raised towing
method be used. Vehicles can be towed with the front
wheels on the ground for extended distances at speeds not exceeding 48 km/h (30 mph) (Fig. 11). (1) Attach the J-hooks around the axle shaft tubes
outboard of the rear springs. (2) Position and center the sling under and for­
ward of the rear bumper. (3) Attach safety chains (with pads) at each end of
the rear bumper.
(4) Turn the ignition switch to the OFF position to
unlock the steering wheel. (5) Clamp the steering wheel with the front wheels
in the straight ahead position.

CAUTION:
Do not use the steering
column
lock
to

secure
front
wheel
in the straight-ahead
position.

(6) Shift the transmission to NEUTRAL.

POSITION CENTER BAR FORWARD
OF
BUMPER
-
/
J-HOOKS OUTBOARD
OF
SPRINGS
RN967A

Fig. 11 Rear-End
Raised
Towing
FRONT'END RAISED TOWING If a vehicle cannot be towed from the rear, the
front-end raised towing method normally can be
used (Fig. 12). (1) Center the sling with the bumper and position
it at the frame front crossmember.

CAUTION:
Use tow
chains
with
J-hooks
for
con­
necting
to the
disabled
vehicle's
lower
suspension
arms.
Never use
T-hooks.

(2) Route the J-hooks and tow chains over the
steering linkage outboard of the coil spring.
(3) Attach the J-hooks to the outer end of the
lower suspension arms.
(4) Raise the vehicle.
(5.) Attach the safety chains to the disabled vehicle
at the frame rails.
Vehicles equipped with a MANUAL TRANSMIS­
SION can be towed with the rear wheels on the

8D
- 2
IGNITION
SYSTEMS

•

A/C
CLUTCH RELAY STARTER RELAY
DATA LINK CONTROL

CONNECTOR
MODULE J9314-164
Fig.
1
Auto
Shut Down
Relay

CAMSHAFT POSITION SENSOR
The camshaft position sensor is located in the igni­
tion distributor (Fig. 2) on all engines.
Fig.
2 Camshaft Position
Sensor—
Typical

The camshaft position sensor contains a hall effect
device called a sync signal generator to generate a
fuel sync signal. This sync signal generator detects a
rotating pulse ring (shutter) on the distributor shaft.
The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction
with the crankshaft position sensor to differentiate
between fuel injection and spark events. It is also
used to synchronize the fuel injectors with their re­ spective cylinders.
When the leading edge of the pulse ring (shutter)
enters the sync signal generator, the following oc­

curs:
The interruption of magnetic field causes the
voltage to switch high resulting in a sync signal of approximately 5 volts.
When the trailing edge of the pulse ring (shutter)
leaves the sync signal generator, the following oc­

curs:
The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. For component testing, refer to the Diagnostics/Ser­
vice Procedures section of this group. For removal and installation of this component, re­
fer to the Component Removal/Installation section of this group.

CRANKSHAFT
POSITION
SENSOR
The sensor is bolted to the top of cylinder block
near the rear of the right cylinder head (Fig. 3).

Fig.
3 Crankshaft Position Sensor—Typical

*
Engine speed and crankshaft position are provided
through the crankshaft position sensor. The sensor generates pulses that are the input sent to the pow­
ertrain control module (PCM). The PCM interprets
the sensor input to determine the crankshaft posi­
tion. The PCM then uses this position, along with other inputs, to determine injector sequence and ig­
nition timing.
The sensor is a hall effect device combined with an
internal magnet. It is also sensitive to steel within a
certain distance from it.

SENSOR
OPERATION-3.9L
ENGINE
The flywheel/drive plate has groups of notches at
its outer edge. On 3.9L V-6 engines, there are three sets of double notches and three sets of single
notches (Fig.
4).

The notches cause a pulse to be generated when
they pass under the sensor. The pulses are the input to the PCM.
The engine will not operate if the PCM does not re­
ceive a crankshaft position sensor input.
For component testing, refer to the Diagnostics/Ser­
vice Procedures section of this group.

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.

TRANSFER

CASE
TRANSFER

CASE
ENGINE
REAR

SUPPORT PLATE
EXTENSION

ASSEMBLY

TRANSMISSION
SUPPORT
SPACER
SPACER

UPPER

INSULATOR
INSULATOR
MOUNTING

PLATE

LOWER

INSULATOR

fT^RAIL
J9109-244
Fig,
7 Rear Engine Support—4WD
with
Automatic
Transmission

(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.
INSULATOR
MOUNTING
PLATE
SPACER

UPPER

L\ f
INSULATOR

NUT®

RAIL

ASSEMBLY
LOWER
INSULATOR

l6ff
RAIL
I
J9109-245

Fig.
8 Rear
Engine
Support—4WD
with
Manual

Transmission
(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:

manifold.
DO
NOT lift the
engine
by the
intake

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

•

5.2L
ENGINE
9 - 51 (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 an 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 N-m (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 the starter motor (refer to Group 8B,
Battery/Starter/Generator Service). (12) Connect power steering hoses, if so 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 procedure). (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.

CYLIiiER
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

J9209-105

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.

9
- 80 5.9L
ENGINE

•

TRANSFER
CASE
TRANSFER

CASE
ENGINE REAR
SUPPORT
PLATE
INSULATOR

MOUNTING
PLATE

LOWER

INSULATOR

\7"
RAIL
1
J9109-244

Fig.
7 Rear
Engine
Support—4WD
with
Automatic
Transmission
(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.
INSULATOR

MOUNTING
PLATE
SPACER

UPPER

INSULATOR

NUT®

LOWER

INSULATOR
J9109-245

Fig.
8 Rear
Engine
Support—4WD
with
Manual

Transmission
(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:

manifold.
DO
NOT
lift
the engine by the intake
(23) Install an engine lifting fixture.
(24) Remove engine front mount bolts.

•

5.9L ENGINE
9-81 (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 an 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 Nnn (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 Nnn (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 the starter motor (refer to Group 8B,
Battery/Starter/Generator Service).
(12) Connect power steering hoses, if so 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 Nnn (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 procedure). (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

J9209-105

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 Nnn (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.