2001 DODGE RAM automatic transmission

8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Clutch Relay.... 8W-30-14, 38, 39
A/C-Heater Control............... 8W-30-14, 39
A/C High Pressure Switch.......... 8W-30-14, 39
A/C Low Pressure Switch.......... 8W-30-14, 39
Accelerator Pedal Position Sensor....... 8W-30-30
Airbag Control Module............ 8W-30-40, 15
Automatic Shut Down Relay . . . 8W-30-3, 17, 18, 19,
22, 23, 24, 25, 26, 27, 28
Battery Temperature Sensor............ 8W-30-4
Battery........................... 8W-30-35
Brake Lamp Switch.............. 8W-30-7, 8, 37
Camshaft Position Sensor........... 8W-30-5, 32
Capacitor......................... 8W-30-28
Central Timer Module C2.......... 8W-30-15, 40
Clockspring...................... 8W-30-7, 34
Controller Antilock Brake.... 8W-30-13, 15, 38, 40
Crankshaft Position Sensor............ 8W-30-13
Cummins Bus...................... 8W-30-29
Data Link Connector...... 8W-30-2, 15, 16, 40, 41
Duty Cycle EVAP/Purge Solenoid....... 8W-30-13
Engine Control Module . . 8W-30-3, 7, 29, 30, 31, 32,
33, 34, 35, 36, 37, 39, 40, 41
Engine Coolant Temperature Sensor . . . 8W-30-9, 34
Engine Oil Pressure Sensor......... 8W-30-33, 13
Fuel Heater Relay................... 8W-30-36
Fuel Heater........................ 8W-30-36
Fuel Injection Pump.............. 8W-30-31, 37
Fuel Injector No. 1............... 8W-30-23, 26
Fuel Injector No. 2............... 8W-30-24, 27
Fuel Injector No. 3............... 8W-30-23, 26
Fuel Injector No. 4............... 8W-30-24, 27
Fuel Injector No. 5............... 8W-30-23, 26
Fuel Injector No. 6............... 8W-30-24, 27
Fuel Injector No. 7............... 8W-30-23, 26
Fuel Injector No. 8............... 8W-30-24, 27
Fuel Injector No. 9.................. 8W-30-26
Fuel Injector No. 10................. 8W-30-27
Fuel Pump Module.................. 8W-30-12
Fuel Pump Relay......... 8W-30-3, 11, 12, 31, 37
Fuel Tank Module................... 8W-30-42
Fuel Transfer Pump................. 8W-30-34
Fuse 3 (PDC)............... 8W-30-2, 11, 29, 37
Fuse 6 (PDC)....................... 8W-30-3
Fuse 7 (PDC)...................... 8W-30-36
Fuse 9 (JB)................. 8W-30-2, 3, 11, 36
Fuse 11 (JB)................. 8W-30-13, 36, 39
Fuse 12 (JB).................... 8W-30-16, 41
Fuse K (PDC).............. 8W-30-17, 18, 19, 22
Fusible Link....................... 8W-30-35
G100............................. 8W-30-12
G102.......................... 8W-30-36, 37
G105..................... 8W-30-2, 16, 20, 21Component Page
G107.......................... 8W-30-34, 36
G113 .......................... 8W-30-14, 34
G200.......................... 8W-30-16, 37
Generator...................... 8W-30-13, 38
Idle Air Control Motor................ 8W-30-9
Ignition Coil 4-Pack................. 8W-30-28
Ignition Coil 6-Pack................. 8W-30-28
Ignition Coil....................... 8W-30-25
Instrument Cluster............ 8W-30-15, 34, 40
Intake Air Heater Relay No. 1......... 8W-30-35
Intake Air Heater Relay No. 2......... 8W-30-35
Intake Air Heater................... 8W-30-35
Intake Air Temperature Sensor...... 8W-30-10, 32
Joint Connector No. 1 . . . 8W-30-4, 7, 12, 36, 37, 42
Joint Connector No. 2......... 8W-30-2, 3, 11, 17,
18, 19, 22, 23, 24, 25,
26, 27, 28, 29, 35, 37
Joint Connector No. 5............. 8W-30-16, 41
Joint Connector No. 7............. 8W-30-15, 40
Junction Block . . . 8W-30-2, 3, 11, 13, 16, 36, 39, 41
Leak Detection Pump................. 8W-30-8
Left Speed Control Switch............. 8W-30-7
Manifold Absolute Pressure Sensor...... 8W-30-10
Manifold Air Pressure Sensor.......... 8W-30-33
Output Speed Sensor................. 8W-30-5
Overdrive Switch.................... 8W-30-6
Overhead Console................ 8W-30-40, 15
Oxygen Sensor 1/1 Left Bank Up . . . 8W-30-18, 22, 20
Oxygen Sensor 1/1 Upstream.......... 8W-30-17
Oxygen Sensor 1/2 Downstream........ 8W-30-17
Oxygen Sensor 1/2 Left Bank Down..... 8W-30-20
Oxygen Sensor 1/2 Pre-Catalyst........ 8W-30-21
Oxygen Sensor 1/3 Post-Catalyst....... 8W-30-21
Oxygen Sensor 2/1 Right Bank Up . . . 8W-30-18, 22,
20
Oxygen Sensor 2/2 Right Bank Down.... 8W-30-20
Oxygen Sensor Downstream Relay...... 8W-30-19
Park/Neutral Position Switch....... 8W-30-13, 38
Power Distribution Center . . 8W-30-2, 3, 11, 17, 18,
22, 23, 24, 25, 26, 27, 28, 29, 36, 37
Powertrain Control Module . . 8W-30-2, 3, 4, 5, 6, 7,
8, 9, 10, 11, 12, 13, 14, 15, 16 17,
18, 19, 20, 21, 22, 23, 24, 25 26, 27,
28, 36, 37,38, 39, 40, 41, 42
PTO Switch..................... 8W-30-14, 34
Radio.......................... 8W-30-15, 40
Right Speed Control Switch............ 8W-30-7
Speed Control Servo.................. 8W-30-5
Throttle Position Sensor.............. 8W-30-14
Transmission Control Relay............ 8W-30-5
Transmission Solenoid Assembly . . . 8W-30-6, 14, 39
Water In Fuel Sensor................ 8W-30-34
BR/BE8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1

POWERTRAIN CONTROL MODULE C2 (GAS) - BLACK 32 WAY
CAV CIRCUIT FUNCTION
25 T13 18DB/BK (A/T) OUTPUT SPEED SENSOR GROUND
26 - -
27 G7 18WT/OR (A/T) VEHICLE SPEED SENSOR SIGNAL
28 T14 18LG/BK (A/T) OUTPUT SPEED SENSOR SIGNAL
29 T25 18LG/WT (A/T) GOVERNOR PRESSURE SENSOR SIGNAL
30 K30 18PK (A/T) TRANSMISSION CONTROL RELAY CONTROL
31 K7 18OR (A/T) 5V SUPPLY
32 - -
POWERTRAIN CONTROL MODULE C3 (DIESEL) - BLACK 32 WAY
CAV CIRCUIT FUNCTION
1 C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
2- -
3 K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL
4 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
5 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
6- -
7- -
8- -
9- -
10 - -
11 V32 18YL/RD SPEED CONTROL SUPPLY
12 A142 14DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
13 T6 18OR/WT (A/T) OVERDRIVE OFF SWITCH SENSE
14 - -
15 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
16 - -
17 - -
18 - -
19 - -
20 - -
21 - -
22 C20 18BR A/C SWITCH SENSE
23 C90 18LG/WT A/C SELECT INPUT
24 V40 18WT/PK BRAKE SWITCH SENSE
25 T125 18DB GENERATOR SOURCE
26 K226 18DB/WT FUEL LEVEL SENSOR SIGNAL
27 D21 18PK/DB SCI TRANSMIT
28 D2 18WT/BK CCD BUS(-)
29 D220 18WT/VT SCI RECEIVE
30 D1 18VT/BR CCD BUS(+)
31 - -
32 V37 18RD/LG SPEED CONTROL SWITCH SIGNAL
BR/BE8W-80 CONNECTOR PIN-OUTS 8W - 80 - 69

material is for use between two machined surfaces.
Do not use on flexible metal flanges.
MOPARtGASKET SEALANT
MopartGasket Sealant is a slow drying, perma-
nently soft sealer. This material is recommended for
sealing threaded fittings and gaskets against leakage
of oil and coolant. Can be used on threaded and
machined parts under all temperatures. This mate-
rial is used on engines with multi-layer steel (MLS)
cylinder head gaskets. This material also will pre-
vent corrosion. MopartGasket Sealant is available in
a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assembling parts using a form-in-place gasket
requires care but it's easier then using precut gas-
kets.
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
MopartGasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the upper crossmember and top core
support.
(4) Remove the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
REMOVAL).(5) Discharge the air conditioning system, if
equipped (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove the A/C compressor with the lines
attached. Set aside.
(8) If equipped, remove the condenser (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - REMOVAL).
(9) Remove the washer bottle.
(10) Remove the fan and fan shroud (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(11) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(12) Remove the generator with the wire connec-
tions (Refer to 8 - ELECTRICAL/CHARGING/GEN-
ERATOR - REMOVAL).
(13) Remove the air cleaner box.
(14) Disconnect the throttle linkage.
(15) Remove throttle body (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/THROTTLE BODY -
REMOVAL).
(16) Remove the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL).
(17) Remove the distributor cap and wiring.
(18) Disconnect the heater hoses.
(19) Disconnect the power steering hoses, if
equipped.
(20) Perform the Fuel System Pressure release
procedure (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY - STANDARD PROCEDURE).Disconnect
the fuel supply line (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/QUICK CONNECT FITTING -
STANDARD PROCEDURE).
(21) On Manual Transmission vehicles, remove the
shift lever.
(22) Raise and support the vehicle on a hoist.
(23) Remove the drain plug and drain the engine
oil.
(24) Remove engine front mount through-bolt nuts.
(25)Automatic TransmissionRemove the trans-
mission cooler line brackets from oil pan.
(26) Disconnect exhaust pipe at manifold.
(27) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).
(28)Manual TransmissionRemove the transmis-
sion.(Refer to 21 - TRANSMISSION/TRANSAXLE/
MANUAL - REMOVAL).
(29) Lower the vehicle.
CAUTION: DO NOT lift the engine by the intake
manifold.
(30) Install an engine lifting fixture.
9 - 12 ENGINE 3.9LBR/BE
ENGINE 3.9L (Continued)

(31) Remove engine from vehicle and install
engine assembly on a repair stand.
INSTALLATION
(1) Remove engine from the repair stand and posi-
tion in the engine compartment. Position the
through-bolt into the support cushion brackets.
(2) Install an engine support fixture.
(3) Raise and support the vehicle on a hoist.
(4)Manual TransmissionInstall the transmis-
sion (Refer to 21 - TRANSMISSION/TRANSAXLE/
MANUAL - INSTALLATION).
(5) Install the starter and connect the starter
wires (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(6) Install exhaust pipe to manifold.
(7)Automatic TransmissionInstall the trans-
mission cooler line brackets on oil pan.
(8) Install engine front mount through-bolt nuts.
Tighten the nuts.
(9) Install the drain plug and tighten to 34 N´m
(25 ft. lbs.) torque.
(10) Lower the vehicle.
(11) Remove engine-lifting fixture.
(12) On Manual Transmission vehicles, install the
shift lever.
(13) Connect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(14) Connect the power steering hoses, if equipped.
(15) Connect the heater hoses.
(16) Install the distributor cap and wiring.
(17) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).(18) Using a new gasket, install throttle body
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE BODY - INSTALLATION).
(19) Connect the throttle linkage.
(20) Install the air cleaner box.
(21) Install the generator and wire connections
(Refer to 8 - ELECTRICAL/STARTING/STARTER
MOTOR - INSTALLATION).
(22) Install radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - INSTALLATION).
(23) Install the fan and fan shroud (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
(24) Install the washer bottle.
(25) If equipped, install the condenser (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - INSTALLATION).
(26) Install the A/C compressor with the lines
attached.
(27) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(28) Evacuate and charge the air conditioning sys-
tem, if equipped (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE).
(29) Install the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
INSTALLATION).
(30) Install the upper crossmember and top core
support.
(31) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(32) Connect the negative cable to the battery.
(33) Start engine and check for leaks.
BR/BEENGINE 3.9L 9 - 13
ENGINE 3.9L (Continued)

TORQUE
TORQUE CHART 3.9L ENGINE
DESCRIPTION N´m In. Ft.
Lbs. Lbs.
Camshaft SprocketÐBolt 68 Ð 50
Camshaft Thrust
PlateÐBolts24 210 Ð
Timing Chain Case
CoverÐ41 Ð 30
Bolts
Connecting Rod
CapÐBolts61 Ð 45
Main Bearing CapÐBolts 115 Ð 85
Crankshaft PulleyÐBolts 24 210 Ð
Cylinder HeadÐBolts
Step 1 68 Ð 50
Step 2 143 Ð 105
Cylinder Head CoverÐ
Bolts11 95 Ð
Engine Support Bracket 41 Ð 30
to Block (4wd)ÐBolts
Exhaust Manifold to
Cylinder34 Ð 25
HeadÐbolts/nuts
FlywheelÐBolts 75 Ð 55
Front InsulatorÐthrough
Bolts95 Ð 70
Front Insulator to
Support
Bracket (4wd)
ÐStud Nut 41 Ð 30
ÐThrough Bolt/Nut 102 Ð 75
Front Insulator to BlockÐ 95 Ð 70
Bolts (2wd)
GeneratorÐMounting
Bolt41 Ð 30
Intake ManifoldÐBolts Refer to Procedure
Oil PanÐBolts 24 215 Ð
Oil PanÐDrain Plug 34 Ð 25
Oil PumpÐMounting
Bolts41 Ð 30
Oil Pump CoverÐBolts 11 95 Ð
Rear Insulator to
BracketÐ68 Ð 50
DESCRIPTION N´m In. Ft.
Lbs. Lbs.
Through-Bolt (2WD)
Rear Insulator to
Crossmember41 Ð 30
Support BracketÐNut
(2WD)
Rear Insulator to 68 Ð 50
CrossmemberÐNuts
(4WD)
Rear Insulator to
Transmission68 Ð 50
Ð Bolts (4WD)
Rear Insulator BracketÐ
Bolts68 Ð 50
(4WD Automatic)
Rear Support Bracket to 41 Ð 30
Crossmember FlangeÐ
Nuts
Rear Support Plate to
Transfer41 Ð 30
CaseÐBolts
Rocker ArmÐBolts 28 Ð 21
Spark Plugs 41 Ð 30
Starter MotorÐMounting
Bolts68 Ð 50
Thermostat HousingÐ
Bolts25 225 Ð
Throttle BodyÐBolts 23 200 Ð
Torque Converter Drive
PlateÐ31 270 Ð
Bolts
Transfer Case to
Insulator204 Ð 150
Mounting PlateÐNuts
Transmission Support
Bracket68 Ð 50
ÐBolts (2WD)
Vibration DamperÐBolt 183 Ð 135
Water Pump to Timing
Chain41 Ð 30
Case CoverÐ Bolts
9 - 18 ENGINE 3.9LBR/BE
ENGINE 3.9L (Continued)

(5) Remove the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
REMOVAL).
(6) Remove the washer bottle from the fan shroud.
(7) Remove the viscous fan/drive (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(8) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(9) Remove the upper crossmember and top core
support.
(10) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(11) Remove the A/C compressor with the lines
attached. Secure compressor out of the way.
(12) Remove generator assembly (Refer to 8 -
ELECTRICAL/CHARGING/GENERATOR - REMOV-
AL).
(13) Remove the air cleaner resonator and duct
work as an assembly.
(14) Disconnect the throttle linkage (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - REMOVAL).
(15) Remove throttle body (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/THROTTLE BODY -
REMOVAL).
(16) Remove the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL).
(17) Remove the distributor cap and wiring.
(18) Disconnect the heater hoses.
(19) Disconnect the power steering hoses, if
equipped.
(20) Perform the Fuel System Pressure Release
procedure (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY - STANDARD PROCEDURE).
(21) Disconnect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(22) On Manual Transmission vehicles, remove the
shift lever (Refer to 21 - TRANSMISSION/TRAN-
SAXLE/MANUAL/SHIFT COVER - REMOVAL).
(23) Raise and support the vehicle on a hoist and
drain the engine oil.
(24) Remove engine front mount thru-bolt nuts.
(25) Disconnect the transmission oil cooler lines
from their retainers at the oil pan bolts.
(26) Disconnect exhaust pipe at manifolds.
(27) Disconnect the starter wires. Remove starter
motor (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - REMOVAL).
(28) Remove the dust shield and transmission
inspection cover.
(29) Remove drive plate to converter bolts (Auto-
matic transmission equipped vehicles).(30) Remove transmission bell housing to engine
block bolts.
(31) Lower the vehicle.
(32) Install an engine lifting fixture.
(33) Separate engine from transmission, remove
engine from vehicle, and install engine assembly on a
repair stand.
INSTALLATION
(1) Remove engine from the repair stand and posi-
tion in the engine compartment. Position the thru-
bolt into the support cushion brackets.
(2) Install engine lifting device.
(3) Lower engine into compartment and align
engine with transmission:
²Manual Transmission: Align clutch disc assem-
bly (if disturbed). Install transmission input shaft
into clutch disc while mating engine and transmis-
sion surfaces. Install two transmission to engine
block mounting bolts finger tight.
²Automatic Transmission: Mate engine and trans-
mission and install two transmission to engine block
mounting bolts finger tight.
(4) Lower engine assembly until engine mount
through bolts rest in mount perches.
(5) Install remaining transmission to engine block
mounting bolts and tighten.
(6) Tighten engine mount through bolts.
(7) Install drive plate to torque converter bolts.
(Automatic transmission models)
(8) Install the dust shield and transmission cover.
(9) Install the starter and connect the starter
wires (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(10) Install exhaust pipe to manifold.
(11) Install the transmission cooler line brackets to
the oil pan.
(12) Install the drain plug and tighten to 34 N´m
(25 ft. lbs.) torque.
(13) Lower the vehicle.
(14) Remove engine lifting fixture.
(15) On Manual Transmission vehicles, install the
shift lever (Refer to 21 - TRANSMISSION/TRAN-
SAXLE/MANUAL/SHIFT COVER - INSTALLA-
TION).
(16) Connect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(17) Connect the power steering hoses, if equipped.
(18) Connect the heater hoses.
(19) Install the distributor cap and wiring.
(20) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).
9 - 70 ENGINE 5.2LBR/BE
ENGINE 5.2L (Continued)

TORQUE
TORQUE CHART 5.2L ENGINE
DESCRIPTION N´m In. Ft.
Lbs. Lbs.
Camshaft SprocketÐBolt 68 Ð 50
Camshaft Thrust PlateÐBolts 24 210 Ð
Chain Case CoverÐBolts 41 Ð 30
Connecting Rod CapÐBolts 61 Ð 45
Main Bearing CapÐBolts 115 Ð 85
Crankshaft PulleyÐBolts 24 210 Ð
Cylinder HeadÐBolts
Step 1 68 Ð 50
Step 2 143 Ð 105
Cylinder Head CoverÐBolts 11 95 Ð
Engine Support Bracket to
BlockÐ41 Ð 30
Bolts (4WD)
Exhaust Manifold to Cylinder
HeadÐ34 Ð 25
Bolts/Nuts
FlywheelÐBolts 75 Ð 55
Front InsulatorÐThrough
bolt/nut95 Ð 70
Front Insulator to Support
BracketÐ
Stud Nut (4WD) 41 Ð 30
Through Bolt/Nut 102 Ð 75
Front Insulator to BlockÐ 95 Ð 70
Bolts (2WD)
GeneratorÐMounting Bolts 41 Ð 30
Intake ManifoldÐBolts Refer to Procedure
Oil PanÐBolts 24 215 Ð
Oil PanÐDrain Plug 34 Ð 25
Oil PumpÐMounting Bolts 41 Ð 30
Oil Pump CoverÐBolts 11 95 Ð
Rear Insulator to BracketÐ
Through68 Ð 50
Bolt (2WD)
Rear Insulator to
Crossmember41 Ð 30
Support BracketÐNut (2WD)
Rear Insulator to
CrossmemberÐ68 Ð 50
Nuts (4WD)
DESCRIPTION N´m In. Ft.
Lbs. Lbs.
Rear Insulator to
TransmissionÐ68 Ð 50
Bolts (4WD)
Rear Insulator BracketÐBolts 68 Ð 50
(4WD Automatic)
Rear Support Plate to
Transfer Case41 Ð 30
ÐBolts
Rocker ArmÐBolts 28 Ð 21
Spark Plugs 41 Ð 30
Starter MotorÐMounting
Bolts68 Ð 50
Thermostat HousingÐBolts 25 225 Ð
Throttle BodyÐBolts 23 200 Ð
Torque Converter Drive
PlateÐBolts31 270 Ð
Transfer Case to Insulator
Mounting204 Ð 150
PlateÐNuts
Transmission Support
BracketÐ68 Ð 50
Bolts (2WD)
Vibration DamperÐBolt 183 Ð 135
Water Pump to Timing Chain
Case41 Ð 30
CoverÐBolts
9 - 76 ENGINE 5.2LBR/BE
ENGINE 5.2L (Continued)

(5) Remove the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
REMOVAL).
(6) Remove the washer bottle from the fan shroud.
(7) Remove the viscous fan/drive (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(8) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(9) Remove the upper crossmember and top core
support.
(10) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(11) Remove the A/C compressor with the lines
attached. Secure compressor out of the way.
(12) Remove generator assembly (Refer to 8 -
ELECTRICAL/CHARGING/GENERATOR - REMOV-
AL).
(13) Remove the air cleaner resonator and duct
work as an assembly.
(14) Disconnect the throttle linkage (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - REMOVAL).
(15) Remove throttle body (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/THROTTLE BODY -
REMOVAL).
(16) Remove the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL).
(17) Remove the distributor cap and wiring.
(18) Disconnect the heater hoses.
(19) Disconnect the power steering hoses, if
equipped.
(20) Perform the Fuel System Pressure Release
procedure (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY - STANDARD PROCEDURE).
(21) Disconnect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(22) On Manual Transmission vehicles, remove the
shift lever (Refer to 21 - TRANSMISSION/TRAN-
SAXLE/MANUAL/SHIFT COVER - REMOVAL).
(23) Raise and support the vehicle on a hoist and
drain the engine oil.
(24) Remove engine front mount thru-bolt nuts.
(25) Disconnect the transmission oil cooler lines
from their retainers at the oil pan bolts.
(26) Disconnect exhaust pipe at manifolds.
(27) Disconnect the starter wires. Remove starter
motor (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - REMOVAL).
(28) Remove the dust shield and transmission
inspection cover.
(29) Remove drive plate to converter bolts (Auto-
matic transmission equipped vehicles).(30) Remove transmission bell housing to engine
block bolts.
(31) Lower the vehicle.
(32) Install an engine lifting fixture.
(33) Separate engine from transmission, remove
engine from vehicle, and install engine assembly on a
repair stand.
INSTALLATION
(1) Remove engine from the repair stand and posi-
tion in the engine compartment. Position the thru-
bolt into the support cushion brackets.
(2) Install engine lifting device.
(3) Lower engine into compartment and align
engine with transmission:
²Manual Transmission: Align clutch disc assem-
bly (if disturbed). Install transmission input shaft
into clutch disc while mating engine and transmis-
sion surfaces. Install two transmission to engine
block mounting bolts finger tight.
²Automatic Transmission: Mate engine and trans-
mission and install two transmission to engine block
mounting bolts finger tight.
(4) Lower engine assembly until engine mount
through bolts rest in mount perches.
(5) Install remaining transmission to engine block
mounting bolts and tighten.
(6) Tighten engine mount through bolts.
(7) Install drive plate to torque converter bolts.
(Automatic transmission models)
(8) Install the dust shield and transmission cover.
(9) Install the starter and connect the starter
wires (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(10) Install exhaust pipe to manifold.
(11) Install the transmission cooler line brackets to
the oil pan.
(12) Install the drain plug and tighten to 34 N´m
(25 ft. lbs.) torque.
(13) Lower the vehicle.
(14) Remove engine lifting fixture.
(15) On Manual Transmission vehicles, install the
shift lever (Refer to 21 - TRANSMISSION/TRAN-
SAXLE/MANUAL/SHIFT COVER - INSTALLA-
TION).
(16) Connect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(17) Connect the power steering hoses, if equipped.
(18) Connect the heater hoses.
(19) Install the distributor cap and wiring.
(20) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).
BR/BEENGINE 5.9L 9 - 127
ENGINE 5.9L (Continued)