1998 DODGE RAM 1500 cylinder head replacement

CLEANINGÐPUSHRODS
Clean the pushrods in a suitable solvent. Rinse in
hot water and blow dry with compressed air. If nec-
essary, use a wire brush or wheel to remove stubborn
deposits.
INSPECTION
INSPECTION - CYLINDER HEAD
Inspect the cylinder head for cracks in the combus-
tion surface. Pressure test any cylinder head that is
visibly cracked. A cylinder head that is cracked
between the injector bore and valve seat can be pres-
sure tested and reused if OK; however, if the crack
extendsintothe valve seat insert bore, the cylinder
headmustbe replaced.
Visually inspect the cylinder block and head com-
bustion surfaces for localized dips or imperfections.
Check the cylinder head and block combustion sur-
faces for overall out-of-flatness. If either the visual or
manual inspection exceeds the limits, then the head
or block must be surfaced.
Check the top surface for damage caused by the
cylinder head gasket leaking between cylinders.
Inspect the block and head surface for nicks, ero-
sion, etc.
Check the head distortion. Maximum overall vari-
ation end to end is 0.305 mm (0.012 inch) (Fig. 13),
and maximum overall variation side to side 0.076
mm ( .003 in.).
DO NOT proceed with the in-chassis overhaul if
the cylinder head or block surface is damaged or not
flat (within specifications).
Check block surface for distortion. Maximum vari-
ation end-to-end is 0.076 mm ( .003 in.), side-to-side
0.051 mm (.002).Visually inspect the cylinder head bolts for dam-
aged threads, corroded/pitted surfaces, or a reduced
diameter due to bolt stretching.
If the bolts are not damaged, their ªfree lengthº
should be measured using the cap screw stretch
gauge provided with the replacement head gasket.
Place the head of the bolt against the base of the slot
and align the bolt with the straight edge of gauge
(Fig. 14). If the end of the bolt touches the foot of the
gauge, the boltmustbe discarded.The maximum
bolt free length is 132.1 mm (5.200 in.).
INSPECTIONÐCROSSHEADS
Inspect the crossheads for cracks and/or excessive
wear on rocker lever and valve tip mating surfaces
(Fig. 15). Replace any crossheads that exhibit abnor-
mal wear or cracks.
Fig. 13 Cylinder Head Combustion Deck Face
1 - STRAIGHT EDGE
2 - FEELER GAUGE
Fig. 14 Head Bolt Stretch Gauge
Fig. 15 Inspecting Crosshead for Cracks
9 - 252 ENGINE 5.9L DIESELDR
CYLINDER HEAD (Continued)

FUEL LEVEL SENDING UNIT /
SENSOR
DESCRIPTION
The fuel gauge sending unit (fuel level sensor) is
attached to the side of the fuel tank module. The
sending unit consists of a float, an arm, and a vari-
able resistor track (card).
OPERATION
The fuel tank module on diesel powered models
has 2 different circuits (wires). Two of these circuits
are used at the fuel gauge sending unit for fuel
gauge operation. The diesel engine does not have a
fuel tank module mounted electric fuel pump. The
electric fuel pump (fuel transfer pump) is mounted to
the engine.
For Fuel Gauge Operation:A constant input
voltage source of about 12 volts (battery voltage) is
supplied to the resistor track on the fuel gauge send-
ing unit. This is fed directly from the Engine Control
Module (ECM).NOTE: For diagnostic purposes,
this 12V power source can only be verified with
the circuit opened (fuel tank module electrical
connector unplugged). With the connectors
plugged, output voltages will vary from about .6
volts at FULL, to about 7.0 volts at EMPTY.The
resistor track is used to vary the voltage (resistance)
depending on fuel tank float level. As fuel level
increases, the float and arm move up, which
decreases voltage. As fuel level decreases, the float
and arm move down, which increases voltage. The
varied voltage signal is returned back to the ECM
through the sensor return circuit.
Both of the electrical circuits between the fuel
gauge sending unit and the ECM are hard-wired (not
multi-plexed). After the voltage signal is sent from
the resistor track, and back to the ECM, the ECM
will interpret the resistance (voltage) data and send
a message across the multi-plex bus circuits to the
instrument panel cluster. Here it is translated into
the appropriate fuel gauge level reading. Refer to
Instrument Panel for additional information.
REMOVAL
REMOVAL/INSTALLATION
For diesel removal and installation procedures,
refer to the gas section of Fuel System/Fuel Delivery.
See Fuel Level Sending Unit/Sensor Removal/Instal-
lation.
FUEL LINES
DESCRIPTION
Low-Pressure Lines Are:
²the fuel supply line from fuel tank to fuel trans-
fer (lift) pump.
²the fuel return line back to fuel tank.
²the fuel drain (manifold) line at rear of cylinder
head.
²the fuel supply line from fuel filter to fuel injec-
tion pump.
²the fuel injection pump return line.
High-Pressure Lines Are:
²the fuel line from fuel injection pump to fuel
rail.
²the 6 fuel lines from fuel rail up to injector con-
nector tubes
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
DIESEL FUEL UNDER EXTREME PRESSURE FROM
THE INJECTION PUMP TO THE FUEL INJECTORS.
THIS MAY BE AS HIGH AS 160,000 KPA (23,206
PSI). USE EXTREME CAUTION WHEN INSPECTING
FOR HIGH-PRESSURE FUEL LEAKS. INSPECT FOR
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD. HIGH FUEL INJECTION PRESSURE
CAN CAUSE PERSONAL INJURY IF CONTACT IS
MADE WITH THE SKIN.
OPERATION
High-Pressure Lines
CAUTION: The high-pressure fuel lines must be
held securely in place in their holders. The lines
cannot contact each other or other components. Do
not attempt to weld high-pressure fuel lines or to
repair lines that are damaged. If lines are ever
kinked or bent, they must be replaced. Use only the
recommended lines when replacement of high-pres-
sure fuel line is necessary.
High-pressure fuel lines deliver fuel (under pres-
sure) of up to approximately 160,000 kPa (23,206
PSI) from the injection pump to the fuel injectors.
The lines expand and contract from the high-pres-
sure fuel pulses generated during the injection pro-
cess. All high-pressure fuel lines are of the same
length and inside diameter. Correct high-pressure
fuel line usage and installation is critical to smooth
engine operation.
DRFUEL DELIVERY - DIESEL 14 - 57

WARNING: USE EXTREME CAUTION WHEN
INSPECTING FOR HIGH-PRESSURE FUEL LEAKS.
INSPECT FOR HIGH-PRESSURE FUEL LEAKS WITH
A SHEET OF CARDBOARD. HIGH FUEL INJECTION
PRESSURE CAN CAUSE PERSONAL INJURY IF
CONTACT IS MADE WITH THE SKIN.
DIAGNOSIS AND TESTING - HIGH-PRESSURE
FUEL LINE LEAKS
High-pressure fuel line leaks can cause starting
problems and poor engine performance.
WARNING: DUE TO EXTREME FUEL PRESSURES
OF UP TO 160,000 kPa (23,206 PSI), USE EXTREME
CAUTION WHEN INSPECTING FOR HIGH-PRES-
SURE FUEL LEAKS. DO NOT GET YOUR HAND OR
A FINGER NEAR A SUSPECTED LEAK. INSPECT
FOR HIGH-PRESSURE FUEL LEAKS WITH A SHEET
OF CARDBOARD. HIGH FUEL INJECTION PRES-
SURE CAN CAUSE PERSONAL INJURY IF CON-
TACT IS MADE WITH THE SKIN.
Start the engine. Move the cardboard (Fig. 13) over
the suspected high-pressure fuel line leak, and check
for fuel spray onto the cardboard. If line is leaking,
retorque line. Replace damaged, restricted or leaking
high-pressure fuel lines with the correct replacement
line.
CAUTION: The high-pressure fuel lines must be
clamped securely in place in the holders. The lines
cannot contact each other or other components. Do
not attempt to weld high-pressure fuel lines or to
repair lines that are damaged. Only use the recom-
mended lines when replacement of high-pressure
fuel line is necessary.
REMOVAL
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system com-
ponents. This especially includes the fuel injectors,
high-pressure fuel lines and fuel injection pump.
Very tight tolerances are used with these parts. Dirt
contamination could cause rapid part wear and pos-
sible plugging of fuel injector nozzle tip holes. This
in turn could lead to possible engine misfire.
Always wash/clean any fuel system component
thoroughly before disassembly and then air dry.
Cap or cover any open part after disassembly.
Before assembly, examine each part for dirt, grease
or other contaminants and clean if necessary. When
installing new parts, lubricate them with clean
engine oil or clean diesel fuel only.
(1) Disconnect both negative battery cables from
both batteries. Cover and isolate ends of cables.(2) Thoroughly clean fuel lines at both ends.
(3) If removing fuel line at either #1 or #2 cylinder,
the intake manifold air heater elements must first be
removed from top of intake manifold. Refer to Intake
Air Heater Removal / Installation for procedures.
(4) If removing fuel line at #6 cylinder, a bracket
(Fig. 14) is located above fuel line connection at cyl-
inder head. Two bolts secure this bracket to rear of
cylinder head. The upper bolt hole is slotted. Loosen
(but do not remove) these 2 bracket bolts. Tilt
bracket down to gain access to #6 fuel line connec-
tion.
(5) Remove engine lift bracket (if necessary).
(6) Remove necessary insulated fuel line support
clamps (Fig. 15) and bracket bolts at intake manifold.
DO NOT remove insulators from fuel lines.
(7) Place shop towels around fuel lines at fuel rail
and injectors. If possible, do not allow fuel to drip
down side of engine.
CAUTION: WHEN LOOSENING OR TIGHTENING
HIGH-PRESSURE LINES ATTACHED TO A SEPA-
RATE FITTING (Fig. 16) , USE A BACK-UP WRENCH
ON FITTING. DO NOT ALLOW FITTING TO ROTATE.
DAMAGE TO BOTH FUEL LINE AND FITTING WILL
RESULT.
(8) Carefully remove each fuel line from engine.
Note position of each while removing.Do not bend
lines while removing.
Fig. 13 TYPICAL TEST FOR LEAKS USING
CARDBOARD
1 - HIGH-PRESSURE LINE
2 - CARDBOARD
3 - TYPICAL HIGH-PRESSURE FITTING
14 - 58 FUEL DELIVERY - DIESELDR
FUEL LINES (Continued)

when a minimum discharge pressure of 2756 kPa
(400 psi) is reached.
The high pressure relief valve vents only enough
refrigerant to reduce the system pressure, and then
re-seats itself. The majority of the refrigerant is con-
served in the system. If the valve vents refrigerant, it
does not mean that the valve is faulty.
The high pressure relief valve is a factory-cali-
brated unit. The valve cannot be adjusted or
repaired, and must not be removed or otherwise dis-
turbed. The valve is only serviced as a part of the
compressor assembly.
DIAGNOSIS AND TESTING - A/C COMPRESSOR
When investigating an air conditioning related
noise, you must first know the conditions under
which the noise occurs. These conditions include:
weather, vehicle speed, transmission in gear or neu-
tral, engine speed, engine temperature, and any
other special conditions. Noises that develop during
air conditioning operation can often be misleading.
For example: What sounds like a failed front bearing
or connecting rod, may be caused by loose bolts, nuts,
mounting brackets, or a loose compressor clutch
assembly.
Drive belts are speed sensitive. At different engine
speeds and depending upon belt tension, belts can
develop noises that are mistaken for a compressor
noise. Improper belt tension can cause a misleading
noise when the compressor clutch is engaged, which
may not occur when the compressor clutch is disen-
gaged. Check the serpentine drive belt condition and
tension as described in Cooling before beginning this
procedure.
(1) Select a quiet area for testing. Duplicate the
complaint conditions as much as possible. Switch the
compressor on and off several times to clearly iden-
tify the compressor noise. Listen to the compressor
while the clutch is engaged and disengaged. Probe
the compressor with an engine stethoscope or a long
screwdriver with the handle held to your ear to bet-
ter localize the source of the noise.
(2) Loosen all of the compressor mounting hard-
ware and retighten. Tighten the compressor clutch
mounting nut. Be certain that the clutch coil is
mounted securely to the compressor, and that the
clutch plate and rotor are properly aligned and have
the correct air gap (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS/A/C COMPRESSOR
CLUTCH - INSTALLATION).
(3) To duplicate a high-ambient temperature condi-
tion (high head pressure), restrict the air flow
through the condenser. Install a manifold gauge set
or a DRBIIItscan tool to be certain that the dis-
charge pressure does not exceed 2760 kPa (400 psi).(4) Check the refrigerant system plumbing for
incorrect routing, rubbing or interference, which can
cause unusual noises. Also check the refrigerant lines
for kinks or sharp bends that will restrict refrigerant
flow, which can cause noises (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE).
(5) If the noise is from opening and closing of the
high pressure relief valve, recover, evacuate and
recharge the refrigerant system (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE), (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE - REFRIGERANT SYSTEM EVACU-
ATE) and (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT SYSTEM CHARGE). If the high
pressure relief valve still does not seat properly,
replace the compressor (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING/A/C COMPRES-
SOR - REMOVAL).
(6) If the noise is from liquid slugging on the suc-
tion line, replace the accumulator (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/AC-
CUMULATOR - REMOVAL) and check the refriger-
ant oil level and the refrigerant system charge (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/REFRIGERANT OIL - STANDARD PROCE-
DURE) (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/ACCUMULATOR -
REMOVAL). If after replacing the accumulator the
slugging condition still exists then replace the com-
pressor.(Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/A/C COMPRESSOR - REMOVAL).
(7) If the liquid slugging condition continues fol-
lowing accumulator replacement, replace the com-
pressor and repeat Step 1.
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
NOTE: The A/C compressor may be removed and
repositioned without disconnecting the refrigerant
lines or discharging the refrigerant system. Dis-
charging is not necessary if servicing the compres-
sor clutch, clutch coil, engine, engine cylinder head
or the generator.
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
DRPLUMBING 24 - 49
A/C COMPRESSOR (Continued)

ENGINE COOLANT TEMPERATURE
SENSOR - REMOVAL...................7-39
ENGINE COOLANT THERMOSTAT -
3.7L/4.7L - DESCRIPTION...............7-44
ENGINE COOLANT THERMOSTAT -
3.7L/4.7L - INSTALLATION..............7-45
ENGINE COOLANT THERMOSTAT -
3.7L/4.7L - OPERATION.................7-44
ENGINE COOLANT THERMOSTAT -
3.7L/4.7L - REMOVAL..................7-45
ENGINE COOLANT THERMOSTAT - 5.9L
DIESEL - DESCRIPTION................7-46
ENGINE COOLANT THERMOSTAT - 5.9L
DIESEL - INSTALLATION................7-47
ENGINE COOLANT THERMOSTAT - 5.9L
DIESEL - OPERATION..................7-46
ENGINE COOLANT THERMOSTAT - 5.9L
DIESEL - REMOVAL....................7-47
ENGINE COOLANT THERMOSTAT - 8.0L -
DESCRIPTION........................7-48
ENGINE COOLANT THERMOSTAT - 8.0L -
INSTALLATION........................7-49
ENGINE COOLANT THERMOSTAT - 8.0L -
OPERATION..........................7-48
ENGINE COOLANT THERMOSTAT - 8.0L -
REMOVAL...........................7-49
ENGINE COOLANT THERMOSTAT-5.7L -
DESCRIPTION........................7-41
ENGINE COOLANT THERMOSTAT-5.7L -
INSTALLATION........................7-43
ENGINE COOLANT THERMOSTAT-5.7L -
OPERATION..........................7-41
ENGINE COOLANT THERMOSTAT-5.7L -
REMOVAL.............................7-42
ENGINE COOLING SYSTEM
REQUIREMENTS - DESCRIPTION.........24-1
ENGINE COOLING SYSTEM, WARNING....24-42
ENGINE DATA PLATE - DESCRIPTION.....9-248
ENGINE DIAGNOSIS - INTRODUCTION -
DIAGNOSIS AND TESTING......9-183,9-4,9-94
ENGINE DIAGNOSIS - LUBRICATION -
DIAGNOSIS AND TESTING..........9-187,9-7
ENGINE DIAGNOSIS - MECHANICAL -
DIAGNOSIS AND TESTING . . . 9-185,9-188,9-233,
9-6,9-92
ENGINE DIAGNOSIS - PERFORMANCE -
DIAGNOSIS AND TESTING......9-183,9-4,9-90
ENGINE FIRING ORDER, 3.7L V-6.........8I-4
ENGINE FIRING ORDER, 4.7L V-8.........8I-4
ENGINE GASKET SURFACE
PREPARATION - STANDARD
PROCEDURE.........................9-10
ENGINE OIL - DIESEL ENGINES -
DESCRIPTION.........................0-2
ENGINE OIL AND LUBRICANTS -
DESCRIPTION.........................0-1
ENGINE OIL LEAK - DIAGNOSIS AND
TESTING..................9-152,9-220,9-64
ENGINE OIL LEVEL - STANDARD
PROCEDURE........................9-292
ENGINE OIL PRESSURE - DIAGNOSIS
AND TESTING.......................9-289
ENGINE OIL PRESSURE - DIAGNOSIS
AND TESTING, CHECKING.....9-152,9-220,9-65
ENGINE OIL SERVICE - STANDARD
PROCEDURE..........9-153,9-222,9-292,9-71
ENGINE, SPECIAL TOOLS - 4.7L.........9-103
ENGINE, SPECIAL TOOLS - 5.7L.........9-196
ENGINE, SPECIAL TOOLS - 5.9L DIESEL . . 9-246
ENGINE, SPECIFICATIONS - 5.7L........9-192
ENGINE TEMPERATURE GAUGE -
DESCRIPTION.......................8J-24
ENGINE TEMPERATURE GAUGE -
OPERATION.........................8J-24
ENGINE TIMING - VERIFICATION -
STANDARD PROCEDURE...............9-167
ENGINES - CLEANING, RADIATOR FAN -
GAS................................7-34
ENGINES - DESCRIPTION, COOLANT
RECOVERY CONTAINER- GAS
............7-33
ENGINES - DESCRIPTION, ENGINE OIL -
DIESEL
..............................0-2
ENGINES - DESCRIPTION, FAN DRIVE
VISCOUS CLUTCH-GAS
.................7-50
ENGINES - INSPECTION, RADIATOR FAN
- GAS
...............................7-34
ENGINES - INSTALLATION, 3.7, 4.7 AND
5.7L
..........................24-53,24-55ENGINES - INSTALLATION, COOLANT
RECOVERY CONTAINER- GAS............7-33
ENGINES - INSTALLATION, RADIATOR
FAN - GAS...........................7-34
ENGINES - OPERATION, COOLANT
RECOVERY CONTAINER- GAS............7-33
ENGINES - OPERATION, FAN DRIVE
VISCOUS CLUTCH-GAS.................7-50
ENGINES - REMOVAL, 3.7, 4.7 AND 5.7L . 24-52,
24-55
ENGINES - REMOVAL, COOLANT
RECOVERY CONTAINER- GAS............7-33
ENGINES - REMOVAL, RADIATOR FAN -
GAS................................7-33
ENGINES - STANDARD PROCEDURE,
DRAINING COOLING SYSTEM - ALL
GAS................................7-17
ENGINES - STANDARD PROCEDURE,
REFILLING COOLING SYSTEM - ALL
GAS................................7-18
ENHANCED SEATBELT REMINDER
PROGRAMMING - STANDARD
PROCEDURE........................8J-35
ENTRY MODULE - DESCRIPTION,
REMOTE KEYLESS....................8N-7
ENTRY MODULE - DIAGNOSIS AND
TESTING, REMOTE KEYLESS............8N-7
ENTRY MODULE - INSTALLATION,
REMOTE KEYLESS....................8N-8
ENTRY MODULE - OPERATION, REMOTE
KEYLESS............................8N-7
ENTRY MODULE - REMOVAL, REMOTE
KEYLESS............................8N-7
ENTRY TRANSMITTER - DIAGNOSIS AND
TESTING, REMOTE KEYLESS..............8N-8
ENTRY TRANSMITTER -
SPECIFICATIONS, REMOTE KEYLESS......8N-9
EQUIPMENT - STANDARD PROCEDURE,
REFRIGERANT SYSTEM SERVICE........24-46
ERASING TRANSMITTER CODES -
STANDARD PROCEDURE..............8M-12
ETC INDICATOR - DESCRIPTION.........8J-25
ETC INDICATOR - OPERATION..........8J-25
EVACUATE - STANDARD PROCEDURE,
REFRIGERANT SYSTEM...............24-47
EVAP SYSTEM - DESCRIPTION..........25-10
EVAP SYSTEM - TORQUE..............25-11
EVAPORATOR - DESCRIPTION, A/C.......24-59
EVAPORATOR - INSTALLATION, A/C......24-60
EVAPORATOR - OPERATION, A/C........24-59
EVAPORATOR - REMOVAL, A/C..........24-60
EVAPORATOR TEMPERATURE SENSOR -
DESCRIPTION.......................24-22
EVAPORATOR TEMPERATURE SENSOR -
INSTALLATION.......................24-22
EVAPORATOR TEMPERATURE SENSOR -
OPERATION.........................24-22
EVAPORATOR TEMPERATURE SENSOR -
REMOVAL..........................24-22
EVAP/PURGE SOLENOID - DESCRIPTION . . 25-12
EVAP/PURGE SOLENOID - INSTALLATION . 25-12
EVAP/PURGE SOLENOID - OPERATION....25-12
EVAP/PURGE SOLENOID - REMOVAL.....25-12
EXHAUST MANIFOLD - CLEANING . . 9-163,9-226,
9-298
EXHAUST MANIFOLD - DESCRIPTION....9-161,
9-226,9-74
EXHAUST MANIFOLD - INSPECTION.....9-163,
9-227,9-298
EXHAUST MANIFOLD - INSTALLATION . . . 9-164,
9-227,9-298,9-74
EXHAUST MANIFOLD - OPERATION......9-226
EXHAUST MANIFOLD - REMOVAL . . 9-161,9-226,
9-298,9-74
EXHAUST PIPE - INSPECTION.......11-7,11-8
EXTENSION HOUSING BUSHING AND
SEAL - INSTALLATION................21-440
EXTENSION HOUSING BUSHING AND
SEAL - REMOVAL
...................21-440
EXTENSION HOUSING SEAL -
INSTALLATION
. . . 21-128,21-201,21-507,21-536,
21-85
EXTENSION HOUSING SEAL - REMOVAL
. 21-128,
21-201,21-507,21-536,21-85
EXTENSION HOUSING SEAL AND DUST
BOOT - INSTALLATION
.........21-476,21-571
EXTENSION HOUSING SEAL AND DUST
BOOT - REMOVAL
.............21-476,21-571EXTERIOR - DESCRIPTION, LAMPS/
LIGHTING...........................8L-2
EXTERIOR - DIAGNOSIS AND TESTING,
LAMPS/LIGHTING.....................8L-3
EXTERIOR - OPERATION, LAMPS/
LIGHTING...........................8L-2
EXTERIOR HANDLE - INSTALLATION.....23-21,
23-30
EXTERIOR HANDLE - REMOVAL....23-20,23-30
EXTERIOR LAMPS, SPECIFICATIONS......8L-7
EXTERIOR NAME PLATES -
INSTALLATION.......................23-38
EXTERIOR NAME PLATES - REMOVAL....23-38
FAILURE - DIAGNOSIS AND TESTING,
CYLINDER HEAD GASKET..............9-199
FAN - 5.9L DIESEL - CLEANING,
RADIATOR...........................7-35
FAN - 5.9L DIESEL - INSPECTION,
RADIATOR...........................7-35
FAN - 5.9L DIESEL - INSTALLATION,
RADIATOR...........................7-36
FAN - 5.9L DIESEL - REMOVAL,
RADIATOR...........................7-35
FAN - GAS ENGINES - CLEANING,
RADIATOR...........................7-34
FAN - GAS ENGINES - INSPECTION,
RADIATOR...........................7-34
FAN - GAS ENGINES - INSTALLATION,
RADIATOR...........................7-34
FAN - GAS ENGINES - REMOVAL,
RADIATOR...........................7-33
FAN DRIVE - DIAGNOSIS AND TESTING,
ELECTRONICALLY CONTROLLED
VISCOUS............................7-52
FAN DRIVE - DIAGNOSIS AND TESTING,
VISCOUS............................7-50
FAN DRIVE VISCOUS CLUTCH - 5.9L
DIESEL - DESCRIPTION................7-52
FAN DRIVE VISCOUS CLUTCH - 5.9L
DIESEL - OPERATION..................7-52
FAN DRIVE VISCOUS CLUTCH-GAS
ENGINES - DESCRIPTION...............7-50
FAN DRIVE VISCOUS CLUTCH-GAS
ENGINES - OPERATION.................7-50
FASCIA - INSTALLATION, FRONT.........13-3
FASCIA - REMOVAL, FRONT.............13-2
FASTENER IDENTIFICATION -
DESCRIPTION......................Intro.-5
FASTENER USAGE - DESCRIPTION......Intro.-8
FENDER - INSTALLATION, FRONT........23-39
FENDER - INSTALLATION, REAR.........23-44
FENDER - REMOVAL, FRONT...........23-39
FENDER - REMOVAL, REAR............23-44
FENDER MARKER LAMP - INSTALLATION . 8L-18
FENDER MARKER LAMP - REMOVAL.....8L-17
FENDER RAIL REPAIR - STANDARD
PROCEDURE, HYDROFORM............13-11
FILL - STANDARD PROCEDURE,
TRANSMISSION...............21-204,21-368
FILL DOOR - INSTALLATION, FUEL.......23-39
FILL DOOR - REMOVAL, FUEL..........23-39
FILLER CAP - DESCRIPTION, FUEL.......25-13
FILLER CAP - OPERATION, FUEL........25-13
FILTER - INSTALLATION, INLET..........14-20
FILTER - INSTALLATION, OIL . 9-155,9-223,9-293,
9-70
FILTER - REMOVAL, INLET.............14-20
FILTER - REMOVAL, OIL . 9-154,9-223,9-293,9-70
FILTER - STANDARD PROCEDURES,
WATER DRAINING AT FUEL............14-47
FILTER / WATER SEPARATOR -
DESCRIPTION, FUEL..................14-50
FILTER / WATER SEPARATOR -
INSTALLATION, FUEL.................14-50
FILTER / WATER SEPARATOR -
OPERATION, FUEL....................14-50
FILTER / WATER SEPARATOR -
REMOVAL, FUEL.....................14-50
FILTER REPLACEMENT - STANDARD
PROCEDURE, FLUID
...........21-203,21-367
FILTER/PRESSURE REGULATOR -
DESCRIPTION, FUEL
...................14-5
FILTER/PRESSURE REGULATOR -
OPERATION, FUEL
.....................14-6
FINESSE SANDING/BUFFING &
POLISHING - DESCRIPTION
............23-74
FINISH - DESCRIPTION, BASECOAT/
CLEARCOAT
.........................23-73
12 INDEXDR
Description Group-Page Description Group-Page Description Group-Page

LATCH STRIKER - INSTALLATION . . 23-17,23-23,
23-33
LATCH STRIKER - REMOVAL . 23-16,23-23,23-33
LATCH STRIKER / SECONDARY CATCH -
INSTALLATION.......................23-48
LATCH STRIKER / SECONDARY CATCH -
REMOVAL..........................23-47
LD & HD EXCEPT 4X4 HD -
INSTALLATION, ALL..................19-14
LD & HD EXCEPT 4X4 HD - REMOVAL,
ALL ...............................19-14
LD FRONT - INSTALLATION, PROPELLER
SHAFT...............................3-7
LD FRONT - REMOVAL, PROPELLER
SHAFT...............................3-6
LEAD - DIAGNOSIS AND TESTING,
TIRE/VEHICLE........................22-8
LEAK - DIAGNOSIS AND TESTING,
CONVERTER HOUSING FLUID....21-144,21-318
LEAK - DIAGNOSIS AND TESTING,
ENGINE OIL................9-152,9-220,9-64
LEAK DETECTION ASSY - DESCRIPTION,
NATURAL VAC.......................25-23
LEAK DETECTION ASSY - INSTALLATION,
NATURAL VAC.......................25-25
LEAK DETECTION ASSY - OPERATION,
NATURAL VAC.......................25-23
LEAK DETECTION ASSY - REMOVAL,
NATURAL VAC.......................25-24
LEAK DETECTION PUMP - DESCRIPTION . . 25-13
LEAK DETECTION PUMP - INSTALLATION . 25-16
LEAK DETECTION PUMP - OPERATION....25-14
LEAK DETECTION PUMP - REMOVAL.....25-16
LEAKAGE - DIAGNOSIS AND TESTING,
CYLINDER COMBUSTION PRESSURE . 9-186,9-8,
9-93
LEAKAGE - DIAGNOSIS AND TESTING,
INTAKE MANIFOLD..............9-159,9-225
LEAKAGE - DIAGNOSIS AND TESTING,
PUMP.............................19-40
LEAKS - DIAGNOSIS AND TESTING,
CHARGE AIR COOLER SYSTEM.........11-16
LEAKS - DIAGNOSIS AND TESTING,
COOLING SYSTEM - TESTING.............7-5
LEAKS - DIAGNOSIS AND TESTING,
HIGH-PRESSURE FUEL LINE............14-58
LEAKS - DIAGNOSIS AND TESTING,
INTAKE MANIFOLD....................9-72
LEAKS - DIAGNOSIS AND TESTING,
REAR SEAL AREA...........9-137,9-209,9-65
LEAKS - DIAGNOSIS AND TESTING,
REFRIGERANT SYSTEM...............24-44
LEAKS - DIAGNOSIS AND TESTING,
WATER .............................23-1
LEAKS - STANDARD PROCEDURE,
REPAIRING.........................22-10
LEARN - STANDARD PROCEDURE,
DRIVE.............................8E-23
LEARN - STANDARD PROCEDURE, TCM
QUICK.............................8E-23
LEFT CYLINDER HEAD - INSTALLATION . . . 9-112
LEFT CYLINDER HEAD - REMOVAL.......9-108
LEFT REAR CABLE - INSTALLATION.......5-39
LEFT REAR CABLE - REMOVAL...........5-38
LENS REPLACEMENT - STANDARD
PROCEDURE, MODULE................8M-3
LEVEL - DIAGNOSIS AND TESTING,
EFFECTS OF INCORRECT FLUID . . 21-201,21-366
LEVEL - STANDARD PROCEDURE,
BRAKE FLUID........................5-23
LEVEL - STANDARD PROCEDURE,
ENGINE OIL.........................9-292
LEVEL - STANDARD PROCEDURE,
REFRIGERANT OIL...................24-69
LEVEL CHECK - STANDARD
PROCEDURE, COOLANT................7-17
LEVEL CHECK - STANDARD
PROCEDURE, FLUID...........21-202,21-366
LEVEL CHECKING - STANDARD
PROCEDURE, POWER STEERING FLUID
. . . 19-43
LEVEL SENDING UNIT / SENSOR -
DESCRIPTION, FUEL
..............14-57,14-6
LEVEL SENDING UNIT / SENSOR -
INSTALLATION, FUEL
..................14-7
LEVEL SENDING UNIT / SENSOR -
OPERATION, FUEL
................14-57,14-6
LEVEL SENDING UNIT / SENSOR -
REMOVAL, FUEL
......................14-7LEVEL SWITCH - DESCRIPTION,
WASHER FLUID......................8R-9
LEVEL SWITCH - INSTALLATION,
WASHER FLUID.....................8R-11
LEVEL SWITCH - OPERATION, WASHER
FLUID..............................8R-9
LEVEL SWITCH - REMOVAL, WASHER
FLUID.............................8R-10
LEVER - ADJUSTMENT, SHIFT . . . 21-446,21-481
LEVER - INSTALLATION, GEAR SHIFT.....19-12
LEVER - INSTALLATION, SHIFT . . . 21-445,21-480
LEVER - REMOVAL, GEAR SHIFT........19-12
LEVER - REMOVAL, SHIFT......21-444,21-479
LEVER KNOB RELEASE - INSTALLATION,
TILT ...............................19-16
LEVER KNOB RELEASE - REMOVAL, TILT . . 19-16
LICENSE PLATE LAMP - INSTALLATION . . . 8L-17
LICENSE PLATE LAMP - REMOVAL.......8L-17
LICENSE PLATE LAMP UNIT -
INSTALLATION.......................8L-17
LICENSE PLATE LAMP UNIT - REMOVAL . . 8L-17
LID - INSTALLATION, CENTER SEAT
BACK..............................23-79
LID - INSTALLATION, UNDER SEAT
STORAGE BIN.......................23-80
LID - REMOVAL, CENTER SEAT BACK....23-79
LID - REMOVAL, UNDER SEAT STORAGE
BIN ...............................23-80
LIFTERS/TAPPETS - CLEANING, SOLID....9-279
LIFTERS/TAPPETS - INSPECTION, SOLID . . . 9-279
LIFTERS/TAPPETS - INSTALLATION,
SOLID.............................9-280
LIFTERS/TAPPETS - REMOVAL, SOLID....9-279
LIGHT DUTY FRONT FRAME RAIL TIP
REPLACEMENT - STANDARD
PROCEDURE.........................13-4
LIGHTER OUTLET - DESCRIPTION,
CIGAR...........................8W-97-2
LIGHTER OUTLET - DIAGNOSIS AND
TESTING, CIGAR...................8W-97-2
LIGHTER OUTLET - OPERATION, CIGAR . 8W-97-2
LIMITING VALVE - DESCRIPTION, FUEL
PRESSURE.........................14-61
LIMITING VALVE - INSTALLATION, FUEL
PRESSURE.........................14-61
LIMITING VALVE - OPERATION, FUEL
PRESSURE.........................14-61
LIMITING VALVE - REMOVAL, FUEL
PRESSURE.........................14-61
LINE - DESCRIPTION, A/C DISCHARGE....24-56
LINE - DESCRIPTION, LIQUID...........24-65
LINE - DESCRIPTION, REFRIGERANT.....24-42
LINE - DESCRIPTION, SUCTION.........24-70
LINE - INSTALLATION, LIQUID..........24-66
LINE - REMOVAL, LIQUID..............24-65
LINE AND TERMINAL REPAIR -
STANDARD PROCEDURE, GRID..........8G-4
LINE COUPLER - DESCRIPTION,
REFRIGERANT.......................24-67
LINE COUPLER - INSTALLATION,
REFRIGERANT.......................24-68
LINE COUPLER - OPERATION,
REFRIGERANT.......................24-67
LINE COUPLER - REMOVAL,
REFRIGERANT.......................24-68
LINE LEAKS - DIAGNOSIS AND TESTING,
HIGH-PRESSURE FUEL................14-58
LINE PRESSURE (LP) SENSOR -
DESCRIPTION......................21-382
LINE PRESSURE (LP) SENSOR -
INSTALLATION......................21-383
LINE PRESSURE (LP) SENSOR -
OPERATION........................21-383
LINE PRESSURE (LP) SENSOR -
REMOVAL.........................21-383
LINES - DESCRIPTION, FUEL.......14-57,14-7
LINES - DESCRIPTION, VACUUM........25-22
LINES - INSTALLATION, FUEL...........14-60
LINES - OPERATION, FUEL.............14-57
LINES - OPERATION, REFRIGERANT......24-42
LINES - REMOVAL, FUEL..............14-58
LINK - INSTALLATION, DRAG...........19-36
LINK - REMOVAL, DRAG...............19-36
LINK CONNECTOR - DESCRIPTION, DATA
. . 8E-3
LINK CONNECTOR - OPERATION, DATA
....8E-3
LINKAGE - INSTALLATION
...............6-12
LINKAGE - LINK/COIL - DESCRIPTION
....19-34
LINKAGE - REMOVAL
..................6-12LINKAGE, SPECIAL TOOLS - STEERING . . . 19-35
LINK/COIL - DESCRIPTION, GEAR........19-20
LINK/COIL - DESCRIPTION, LINKAGE.....19-34
LINK/COIL - INSTALLATION, GEAR.......19-21
LINK/COIL - OPERATION, GEAR.........19-20
LINK/COIL - REMOVAL, GEAR...........19-20
LINK/COIL SUSPENSION - STANDARD
PROCEDURE, ALIGNMENT...............2-5
LIQUID LINE - DESCRIPTION...........24-65
LIQUID LINE - INSTALLATION...........24-66
LIQUID LINE - REMOVAL..............24-65
LOAD FLOOR - INSTALLATION..........23-72
LOAD FLOOR - REMOVAL..............23-71
LOAD FLOOR SUPPORT CYLINDER -
INSTALLATION.......................23-72
LOAD FLOOR SUPPORT CYLINDER -
REMOVAL..........................23-72
LOCATION - DESCRIPTION, CONNECTOR/
GROUND/SPLICE...................8W-91-1
LOCATIONS - SPECIFICATIONS, SEALER . 23-102
LOCATIONS - SPECIFICATIONS,
STRUCTURAL ADHESIVE..............23-112
LOCATIONS - SPECIFICATIONS, WELD . . . 23-120
LOCK - STANDARD PROCEDURE,
HYDROSTATIC..................9-190,9-240
LOCK CYLINDER - DIAGNOSIS AND
TESTING, IGNITION SWITCH AND KEY....19-11
LOCK CYLINDER - INSTALLATION.......23-24
LOCK CYLINDER - REMOVAL.............23-24
LOCK MOTOR - DESCRIPTION, DOOR.....8N-4
LOCK MOTOR - DIAGNOSIS AND
TESTING, DOOR......................8N-4
LOCK MOTOR - OPERATION, DOOR.......8N-4
LOCK SWITCH - DIAGNOSIS AND
TESTING, POWER.....................8N-4
LOCK SWITCH - INSTALLATION, POWER . . . 8N-4
LOCK SWITCH - REMOVAL, POWER......8N-4
LOCKING RETRACTOR - DESCRIPTION,
AUTOMATIC........................8O-14
LOCKING RETRACTOR - OPERATION,
AUTOMATIC........................8O-14
LOCKS - DESCRIPTION, POWER.........8N-1
LOCKS - DIAGNOSIS AND TESTING,
POWER.............................8N-3
LOCKS - OPERATION, POWER...........8N-2
LOOP ADJUSTER - INSTALLATION, SEAT
BELT TURNING......................8O-55
LOOP ADJUSTER - REMOVAL, SEAT
BELT TURNING......................8O-55
LOOP BRACKETS - INSTALLATION, SEAT
BACK REAR - FOOTMANS..............23-85
LOOP BRACKETS - REMOVAL, SEAT
BACK REAR - FOOTMANS..............23-85
LOW FUEL INDICATOR - DESCRIPTION . . . 8J-30
LOW FUEL INDICATOR - OPERATION.....8J-30
LOWER BALL JOINT - DIAGNOSIS AND
TESTING........................2-19,2-34
LOWER BALL JOINT - INSTALLATION . 2-20,2-35
LOWER BALL JOINT - REMOVAL.....2-19,2-35
LOWER CONTROL ARM BUSHINGS -
2WD (LD) - INSTALLATION..............2-15
LOWER CONTROL ARM BUSHINGS -
2WD (LD) - REMOVAL.................2-13
LOWER CONTROL ARM BUSHINGS -
4WD (LD) - INSTALLATION..............2-14
LOWER CONTROL ARM BUSHINGS -
4WD (LD) - REMOVAL.................2-13
LOWER SURROUND - INSTALLATION,
INSTRUMENT PANEL..................23-59
LOWER SURROUND - REMOVAL,
INSTRUMENT PANEL..................23-59
LOWER SUSPENSION ARM -
INSTALLATION........................2-38
LOWER SUSPENSION ARM - REMOVAL....2-38
LOWER TRIM - INSTALLATION,
B-PILLAR...........................23-64
LOWER TRIM - INSTALLATION,
C-PILLAR...........................23-67
LOWER TRIM - REMOVAL, B-PILLAR.....23-63
LOWER TRIM - REMOVAL, C-PILLAR.....23-66
LOW/REVERSE CLUTCH - ASSEMBLY....21-385
LOW/REVERSE CLUTCH - CLEANING
....21-385
LOW/REVERSE CLUTCH - DISASSEMBLY
. 21-384
LOW/REVERSE CLUTCH - INSPECTION
. . 21-385
LUBRICANTS - DESCRIPTION, ENGINE
OIL
.................................0-1
LUBRICATION - DESCRIPTION
.....9-150,9-220,
9-289,9-61
DRINDEX 19
Description Group-Page Description Group-Page Description Group-Page