2001 DODGE RAM warning

IGNITION SWITCH C1 - BLACK 7 WAY
CAV CIRCUIT FUNCTION
1 A41 14YL IGNITION SWITCH OUTPUT (START)
2 A21 12DB IGNITION SWITCH OUTPUT (RUN-START)
3- -
4 A2 14PK/BK FUSED B(+)
5 A22 14BK/OR IGNITION SWITCH OUTPUT (RUN)
6 A31 12BK/WT IGNITION SWITCH OUTPUT (RUN-ACC)
7 A1 10RD FUSED B(+)
IGNITION SWITCH C2 - GRAY 4 WAY
CAV CIRCUIT FUNCTION
1 Z3 22BK/OR ((HIGHLINE/PREMIUM)) GROUND
1 G75 22TN (BASE) DRIVER DOOR AJAR SWITCH SENSE
2 G26 22LB KEY-IN IGNITION SWITCH SENSE
3- -
4- -
INSTRUMENT CLUSTER C1 - 10 WAY
CAV CIRCUIT FUNCTION
1- -
2 G5 22DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
3 G11 22WT/LG PARK BRAKE SWITCH SENSE
4 Z2 20BK/LG GROUND
5 Z3 20BK/OR GROUND
6 F73 20YL FUSED B(+)
7- -
8 G85 22OR/BK (DIESEL) WAIT-TO-START WARNING INDICATOR DRIVER
9 D2 20WT/BK CCD BUS (-)
10 D1 20VT/BR CCD BUS (+)
INSTRUMENT CLUSTER C2 - 10 WAY
CAV CIRCUIT FUNCTION
1 E2 22OR PANEL LAMPS FEED
2 G29 22BK/WT WASHER FLUID SWITCH SENSE
3 G10 22LG/RD SEAT BELT SWITCH SENSE
4- -
5 E17 18YL/BK DAY BRIGHTNESS SENSE
6 L61 18LG LEFT TURN SIGNAL
7 G13 22DB/RD CHIME REQUEST SIGNAL
8 L60 18TN RIGHT TURN SIGNAL
9 G34 16RD/GY HIGH BEAM INDICATOR DRIVER
10 G107 22GY 4WD SWITCH SENSE
INTAKE AIR HEATER RELAYS (DIESEL)-4WAY
CAV CIRCUIT FUNCTION
1 S22 18OR/BK AIR INTAKE HEATER RELAY CONTROL NO. 2
2 Z12 18BK/TN GROUND
3 S21 18YL/BK AIR INTAKE HEATER RELAY CONTROL NO. 1
4 Z12 18BK/TN GROUND
BR/BE8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47

SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS
CIGAR LIGHTER OUTLET
DESCRIPTION
A cigar lighter is standard equipment on this
model. The cigar lighter is installed in the instru-
ment panel next to the ash receiver, which is located
near the center of the instrument panel, below the
radio. The cigar lighter base is secured by a snap fit
within the instrument panel.
The cigar lighter knob and heating element unit,
and the cigar lighter receptacle unit are available for
service. These components cannot be repaired and, if
faulty or damaged, they must be replaced.
OPERATION
The cigar lighter consists of two major components:
a knob and heating element unit, and the cigar
lighter base or receptacle shell. The receptacle shell
is connected to ground, and an insulated contact in
the bottom of the shell is connected to battery cur-
rent. The cigar lighter receives battery voltage from a
fuse in the junction block only when the ignition
switch is in the Accessory or On positions.
The knob and heating element are encased within
a spring-loaded housing, which also features a sliding
protective heat shield. When the knob and heating
element are inserted in the receptacle shell, the heat-
ing element resistor coil is grounded through its
housing to the receptacle shell. If the cigar lighter
knob is pushed inward, the heat shield slides up
toward the knob exposing the heating element, and
the heating element extends from the housing toward
the insulated contact in the bottom of the receptacle
shell.
Two small spring-clip retainers are located on
either side of the insulated contact inside the bottomof the receptacle shell. These clips engage and hold
the heating element against the insulated contact
long enough for the resistor coil to heat up. When the
heating element is engaged with the contact, battery
current can flow through the resistor coil to ground,
causing the resistor coil to heat.
When the resistor coil becomes sufficiently heated,
excess heat radiates from the heating element caus-
ing the spring-clips to expand. Once the spring-clips
expand far enough to release the heating element,
the spring-loaded housing forces the knob and heat-
ing element to pop back outward to their relaxed
position. When the cigar lighter knob and element
are pulled out of the receptacle shell, the protective
heat shield slides downward on the housing so that
the heating element is recessed and shielded around
its circumference for safety.
DIAGNOSIS & TESTING - CIGAR LIGHTER
For complete circuit diagrams, refer toCigar
Lighterin Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Check the fused ignition switch output (run/ac-
cessory) fuse in the junction block. If OK, go to Step
2. If not OK, repair the shorted circuit or component
as required and replace the faulty fuse.
(2) Turn the ignition switch to the On position.
Check for battery voltage at the fused ignition switch
output (run/accessory) fuse in the junction block. If
OK, go to Step 3. If not OK, repair the open fused
ignition switch output (run/accessory) circuit to the
ignition switch as required.
(3) Turn the ignition switch to the Off position.
Remove the cigar lighter knob and element from the
cigar lighter receptacle. Check for continuity between
the inside circumference of the cigar lighter recepta-
cle and a good ground. There should be continuity. If
OK, go to Step 4. If not OK, go to Step 5.
(4) Turn the ignition switch to the On position.
Check for battery voltage at the insulated contact
located at the back of the cigar lighter receptacle. If
OK, replace the faulty cigar lighter knob and ele-
ment. If not OK, go to Step 5.
(5) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Remove the cigar lighter receptacle from the instru-
ment panel and disconnect the wire harness connec-Terminal Pick Kit 6680
8W - 97 - 2 8W-97 POWER DISTRIBUTIONBR/BE

(1) Turn the ignition switch to the Off position.
(2) To install the IOD fuse, use a thumb to press
the IOD fuse holder unit in fuse cavity 12 firmly into
the JB.
(3) Install the fuse access panel by snapping it
onto the left outboard end of the instrument panel.
JUNCTION BLOCK
DESCRIPTION
An electrical Junction Block (JB) is concealed
behind the left outboard end of the instrument panel
cover (Fig. 5). The JB combines the functions previ-
ously provided by a separate fuseblock module and
relay center, serves to simplify and centralize numer-
ous electrical components, and to distribute electrical
current to many of the accessory systems in the vehi-
cle. It also eliminates the need for numerous splice
connections and serves in place of a bulkhead connec-
tor between many of the engine compartment, instru-
ment panel, and body wire harnesses. The JB houses
up to nineteen blade-type fuses (two standard-type
and seventeen mini-type), up to two blade-type auto-
matic resetting circuit breakers, the electronic combi-
nation turn signal and hazard warning flasher, and
one International Standards Organization (ISO)
micro-relay.The molded plastic JB housing has integral mount-
ing brackets that are secured with two screws to the
left instrument panel end bracket. The left end of the
instrument panel cover has a snap-fit fuse access
panel that can be removed for service of the JB. A
fuse puller and spare fuse holders are located on the
back of the fuse access cover, as well as an adhesive-
backed fuse layout map to ensure proper fuse identi-
fication.
The JB unit cannot be repaired and is only ser-
viced as an assembly. If any internal circuit or the JB
housing is faulty or damaged, the entire JB unit
must be replaced.
OPERATION
All of the circuits entering and leaving the JB do
so through up to nine wire harness connectors, which
are connected to the JB through integral connector
receptacles molded into the JB housing. Internal con-
nection of all of the JB circuits is accomplished by an
intricate combination of hard wiring and bus bars.
Refer toJunction Blockin the index of this service
manual for the location of complete JB circuit dia-
grams.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
Fig. 4 Ignition-Off Draw Fuse
1 - JUNCTION BLOCK
2 - IGNITION-OFF DRAW FUSE AND HOLDER
3 - LEFT INSTRUMENT PANEL END BRACKET
Fig. 5 Junction Block Location
1 - JUNCTION BLOCK
2 - FUSE ACCESS PANEL
8W - 97 - 6 8W-97 POWER DISTRIBUTIONBR/BE
IOD FUSE (Continued)

the instrument panel, below the radio. The power
outlet base is secured by a snap fit within the instru-
ment panel. A plastic protective cap snaps into the
power outlet base when the power outlet is not being
used, and hangs from the power outlet base mount
by an integral bail strap while the power outlet is in
use.
The power outlet receptacle unit and the accessory
power outlet protective cap are available for service.
The power outlet receptacle cannot be repaired and,
if faulty or damaged, it must be replaced.
OPERATION
The power outlet base or receptacle shell is con-
nected to ground, and an insulated contact in the
bottom of the shell is connected to battery current.
The power outlet receives battery voltage from a fuse
in the Power Distribution Center (PDC) at all times.
While the power outlet is very similar to a cigar
lighter base unit, it does not include the two small
spring-clip retainers inside the bottom of the recepta-
cle shell that are used to secure the cigar lighter
heating element to the insulated contact.
DIAGNOSIS & TESTING - POWER OUTLET
For complete circuit diagrams, refer toPower
Outletin Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Check the fused B(+) fuse in the Power Distri-
bution Center (PDC). If OK, go to Step 2. If not OK,
repair the shorted circuit or component as required
and replace the faulty fuse.
(2) Check for battery voltage at the fused B(+) fuse
in the PDC. If OK, go to Step 3. If not OK, repair the
open fused B(+) circuit to the battery as required.
(3) Remove the plastic protective cap from the
power outlet receptacle. Check for continuity between
the inside circumference of the power outlet recepta-
cle and a good ground. There should be continuity. If
OK, go to Step 4. If not OK, go to Step 5.
(4) Check for battery voltage at the insulated con-
tact located at the back of the power outlet recepta-
cle. If not OK, go to Step 5.
(5) Disconnect and isolate the battery negative
cable. Remove the power outlet receptacle from the
instrument panel. Disconnect the wire harness con-
nector from the power outlet receptacle. Check forcontinuity between the ground circuit cavity of the
power outlet wire harness connector and a good
ground. There should be continuity. If OK, go to Step
6. If not OK, repair the open ground circuit to ground
as required.
(6) Connect the battery negative cable. Check for
battery voltage at the fused B(+) circuit cavity of the
power outlet wire harness connector. If OK, replace
the faulty power outlet receptacle. If not OK, repair
the open fused B(+) circuit to the PDC fuse as
required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Pull the cigar lighter knob and element out of
the cigar lighter receptacle base, or unsnap the pro-
tective cap from the power outlet receptacle base
(Fig. 11).
(3) Look inside the cigar lighter or power outlet
receptacle base and note the position of the rectangu-
lar retaining bosses of the mount that secures the
receptacle base to the instrument panel (Fig. 12).
(4) Insert a pair of external snap ring pliers into
the cigar lighter or power outlet receptacle base and
engage the tips of the pliers with the retaining
bosses of the mount.
(5) Squeeze the pliers to disengage the mount
retaining bosses from the receptacle base and, using
a gentle rocking motion, pull the pliers and the
receptacle base out of the mount.
Fig. 11 Cigar Lighter and Power Outlet
1 - RECEPTACLE BASE
2 - KNOB & ELEMENT
3 - MOUNT
4 - WIRE HARNESS CONNECTOR
5 - POWER OUTLET
8W - 97 - 10 8W-97 POWER DISTRIBUTIONBR/BE
POWER OUTLET (Continued)

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

CYLINDER HEAD
DESCRIPTIONÐCYLINDER HEAD
The cast iron cylinder heads (Fig. 5) are mounted
to the cylinder block using eight bolts. The spark
plugs are located in the peak of the wedge between
the valves.
DESCRIPTIONÐCYLINDER HEAD COVER
GASKET
The cylinder head cover gasket (Fig. 6) is a steel-
backed silicone gasket, designed for long life usage.
OPERATIONÐCYLINDER HEAD
The cylinder head closes the combustion chamber
allowing the pistons to compress the air fuel mixture to
the correct ratio for ignition. The valves located in the
cylinder head open and close to either allow clean air
into the combustion chamber or to allow the exhaust
gases out, depending on the stroke of the engine.
OPERATIONÐCYLINDER HEAD COVER
GASKET
The steel-backed silicone gasket is designed to seal
the cylinder head cover for long periods of time
through extensive heat and cold, without failure. The
gasket is designed to be reusable.
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET FAILURE
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
²Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
²Loss of engine power
²Engine misfiring
²Poor fuel economy
²Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
²Engine overheating
²Loss of coolant
²Excessive steam (white smoke) emitting from
exhaust
²Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test in this
section. An engine cylinder head gasket leaking
between adjacent cylinders will result in approxi-
mately a 50±70% reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
Fig. 5 Cylinder Head AssemblyÐ3.9L Engine
1 - SPARK PLUGS
2 - SPARK PLUG
3 - INTAKE VALVE
4 - EXHAUST VALVES
5 - INTAKE VALVES
6 - EXHAUST VALVE
Fig. 6 Cylinder Head Cover Gasket
1 - CYLINDER HEAD COVER GASKET
9 - 22 ENGINE 3.9LBR/BE

COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL
The alloy cast iron cylinder heads (Fig. 7) are held
in place by eight bolts. The spark plugs are located
at the peak of the wedge between the valves.
(1) Disconnect the battery negative cable from the
battery.
(2) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the intake manifold-to-generator
bracket support rod. Remove the generator.
(4) Remove closed crankcase ventilation system.
(5) Disconnect the evaporation control system.
(6) Remove the air cleaner, air in-let hose and res-
onator.
(7) Perform fuel system pressure release procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(8) Disconnect the fuel supply line from the fuel
rail (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
QUICK CONNECT FITTING - STANDARD PROCE-
DURE).
(9) Disconnect accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(10) Remove distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect coolant temperature sending unit
wire.
(13) Disconnect heater hoses and bypass hose.
(14) Disconnect the vacuum supply hoses from the
intake manifold.
(15) Disconnect the fuel injector harness and
secure out of the way.
(16) Remove cylinder head covers and gaskets
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).(17) Remove intake manifold and throttle body as
an assembly. Discard the flange side gaskets and the
front and rear cross-over gaskets.
(18) Remove exhaust manifolds (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
REMOVAL).
(19) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations.
(20) Remove the head bolts from each cylinder
head and remove cylinder heads. Discard the cylin-
der head gasket.
(21) Remove spark plugs.
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
INSPECTION
Inspect all surfaces with a straightedge if there is
any reason to suspect leakage. If out-of-flatness
exceeds 0.00075mm (0.0001in.) times the span length
in any direction, either replace head or lightly
machine the head surface.
FOR EXAMPLE:ÐA 305 mm (12 in.) span is
0.102 mm (0.004 in.) out-of-flat. The allowable out-of-
flat is 305 x 0.00075 (12 x 0.00075) equals 0.23 mm
(0.009 in.). This amount of out-of-flat is acceptable.
The cylinder head surface finish should be
1.78-3.00 microns (70-125 microinches).
Inspect push rods. Replace worn or bent rods.
INSTALLATION
The alloy cast iron cylinder heads (Fig. 7) are held
in place by eight bolts. The spark plugs are located
at the peak of the wedge between the valves.
(1) Position the new cylinder head gaskets onto
the cylinder block.
(2) Position the cylinder heads onto head gaskets
and cylinder block.
(3) Starting at top center, tighten all cylinder head
bolts, in sequence, to 68 N´m (50 ft. lbs.) torque (Fig.
7). Repeat procedure, tighten all cylinder head bolts
to 143 N´m (105 ft. lbs.) torque. Repeat procedure to
confirm that all bolts are at 143 N´m (105 ft. lbs.)
torque.
CAUTION: When tightening the rocker arm bolts, be
sure the piston in that cylinder is NOT at TDC. Con-
tact between the valves and piston could occur.
(4) Install push rods and rocker arm assemblies in
their original positions. Tighten the bolts to 28 N´m
(21 ft. lbs.) torque.
BR/BEENGINE 3.9L 9 - 23
CYLINDER HEAD (Continued)

DIAGNOSIS AND TESTINGÐINTAKE
MANIFOLD LEAKAGE
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS, OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water at the suspected
leak area.
(3) If a change in RPMs, the area of the suspected
leak has been found.
(4) Repair as required.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(3) Remove the A/C compressor (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - REMOVAL).
(4) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(5) Remove the accessory drive bracket.
(6) Remove the air cleaner.
(7) Perform the Fuel System Pressure release pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY - STANDARD PROCEDURE). Disconnect the
fuel lines (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(8) Disconnect the accelerator linkage (Refer to 14
- FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - REMOVAL) and if so equipped,
the speed control and transmission kickdown cables.
(9) Remove the return spring.
(10) Remove the distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect the heat indicator sending unit
wire.
(13) Disconnect the heater hoses and bypass hose.
(14) Remove the closed crankcase ventilation and
evaporation control systems.
(15) Remove intake manifold bolts.
(16) Lift the intake manifold and throttle body out
of the engine compartment as an assembly.
(17) Remove and discard the flange side gaskets
and the front and rear cross-over gaskets.(18) Remove the throttle body (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/THROTTLE BODY -
REMOVAL).
(19) If required, remove the plenum pan and gas-
ket. Discard gasket.
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
The plenum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.
INSTALLATION
(1) If the plenum pan was removed, position a new
gasket and install the plenum pan (Fig. 67). Tighten
bolts in the following sequence:
²Step 1. Tighten bolts to 5.4 N´m (48 in. lbs.)
²Step 2. Tighten bolts to 9.5 N´m (84 in. lbs.)
²Step 3. Check bolts to 9.5 N´m (84 in. lbs.)
(2) Install the flange gaskets. Ensure 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. 69). The words MANIFOLD SIDE should be vis-
ible on the center of each flange gasket.
Fig. 67 Plenum Pan Bolt Tightening Sequence
BR/BEENGINE 3.9L 9 - 53
INTAKE MANIFOLD (Continued)