2002 DODGE RAM fuel cap

(3) Engage the two mounting hooks on the rear of
the overhead console housing in the mounting holes
in the inner roof panel.
(4) Slide the overhead console forward far enough
to align the two latches on the front of the housing
with their receptacles in the inner roof panel.
(5) Push upward firmly and evenly on the front of
the overhead console until each of the two latches is
fully engaged in its receptacle in the inner roof panel.
(6) Close the garage door opener storage bin door.
(7) Reconnect the battery negative cable.
SPECIAL TOOLS
OVERHEAD CONSOLE SPECIAL TOOL
COMPASS/MINI-TRIP
COMPUTER
DESCRIPTION
The compass mini-trip computer is located in the
premium overhead console on models equipped with
this option. Two compass mini-trip computer units
are available. One unit is used on vehicles not
equipped with the Vehicle Theft Security System
(VTSS) option, and the other is used on vehicles with
the VTSS option. Both compass mini-trip computer
units include the electronic control module, a Vacu-
um-Fluorescent Display (VFD), a compass flux-gate
unit and two push button function switches.
Compass mini-trip computer units for vehicles
equipped with the VTSS include a red Light-Emit-
ting Diode (LED) on their electronic circuit board.
This LED protrudes through the bottom of the lens
on the front of the overhead console unit, and serves
as the security indicator lamp. Refer toSecurity
Indicator Lampin Vehicle Theft/Security Systems
for more information on this feature.
The compass mini-trip computer module contains a
central processing unit and interfaces with other
electronic modules in the vehicle on the Chrysler Col-
lision Detection (CCD) data bus network. The CCD
data bus network allows the sharing of sensor infor-
mation. This helps to reduce wire harness complexity,
reduce internal controller hardware, and reduce com-
ponent sensor current loads. At the same time, thissystem provides increased reliability, enhanced diag-
nostics, and allows the addition of many new feature
capabilities.
The compass mini-trip computer provides several
electronic functions and features. Some of the func-
tions and features that the compass mini-trip com-
puter module supports and/or controls, include the
following display options:
²Compass and temperature- provides the out-
side temperature and one of eight compass readings
to indicate the direction the vehicle is facing.
²Compass and compass in degrees- provides
one of eight compass readings to indicate the direc-
tion the vehicle is facing and provides the compass
direction in degrees.
²Trip odometer (ODO)- shows the distance
travelled since the last trip computer reset.
²Average fuel economy (AVG ECO)- shows
the average fuel economy since the last trip computer
reset.
²Instant fuel economy (ECO)- shows the
present fuel economy based upon the current vehicle
distance and fuel used information.
²Distance to empty (DTE)- shows the esti-
mated distance that can be travelled with the fuel
remaining in the fuel tank. This estimated distance
is computed using the average miles-per-gallon from
the last 30 gallons of fuel used.
²Elapsed time (ET)- shows the accumulated
ignition-on time since the last trip computer reset.
²Blank screen- the compass mini-trip VFD is
turned off.
The ambient temperature sensor is hard wired to
the compass mini-trip computer module. Data input
for all other compass mini-trip computer functions,
including VFD dimming level, is received through
CCD data bus messages. The compass mini-trip com-
puter uses its internal programming and all of these
inputs to calculate and display the requested data. If
the data displayed is incorrect, perform the self-diag-
nostic tests as described in this group. If these tests
prove inconclusive, the use of a DRBIIItscan tool
and the proper Diagnostic Procedures manual are
recommended for further testing of the compass
mini-trip computer module and the CCD data bus.
The compass mini-trip computer module cannot be
repaired, and is available for service only as a unit. If
faulty or damaged, the complete module must be
replaced.
OPERATION
The compass mini-trip computer only operates with
the ignition switch in the On position. When the igni-
tion switch is turned to the On position, all of the
segments in the compass mini-trip computer VFD
will be turned on for one second, then the display
Degaussing Tool 6029
BR/BEMESSAGE SYSTEMS 8M - 9
OVERHEAD CONSOLE (Continued)

8W-02 COMPONENT INDEX
Component Page
4WD Switch.......................... 8W-31
A/C Compressor Clutch Relay............ 8W-42
A/C Compressor Clutch................. 8W-42
A/C- Heater Control.................... 8W-42
A/C Heater Temperature Select........... 8W-42
A/C High Pressure Switch............... 8W-42
A/C Low Pressure Switch................ 8W-42
Accelerator Pedal Position Sensor......... 8W-30
Aftermarket Center High Mounted Stop
Lamp............................. 8W-51
Aftermarket Trailer Tow Connector........ 8W-54
Airbag Control Module.................. 8W-43
Ambient Temperature Sensor............ 8W-49
Ash Receiver Lamp.................... 8W-44
Automatic Day/Night Mirror............. 8W-49
Automatic Shut Down Relay............. 8W-30
Auxiliary Battery...................... 8W-20
Back-Up Lamp Switch.................. 8W-51
Back-Up Lamp........................ 8W-51
Battery Temperature Sensor............. 8W-30
Battery............................. 8W-20
Blend Door Actuator................... 8W-42
Blower Motor Relay.................... 8W-42
Blower Motor Resistor Block............. 8W-42
Blower Motor......................... 8W-42
Brake Lamp Switch.................... 8W-51
Brake Pressure Switch............... 8W-34, 35
Bypass Jumper....................... 8W-21
Camshaft Position Sensor............... 8W-30
Capacitor......................... 8W-10, 30
Cargo Lamps........................ 8W-44
Center High Mounted Stop Lamps........ 8W-51
Center Identification Lamp.............. 8W-50
Central Timer Module.................. 8W-45
Cigar Lighter......................... 8W-41
Circuit Breakers...................... 8W-12
Clockspring.................. 8W-33, 41, 43, 47
Clutch Pedal Position Switch............. 8W-21
Combination Flasher................... 8W-52
Controller Antilock Brake............ 8W-34, 35
Crankshaft Position Sensor.............. 8W-30
Cummins Bus........................ 8W-18
Cup Holder Lamp..................... 8W-44
Data Link Connector................... 8W-18
Daytime Running Lamp Module.......... 8W-50
Dome Lamp.......................... 8W-44
Driver Airbag......................... 8W-43
Driver Cylinder Lock Switch............. 8W-39
Driver Door Ajar Switch................ 8W-45
Driver Door Lock Motor................. 8W-61
Driver Door Window/Lock Switch...... 8W-60, 61
Driver Heated Seat Cushion............. 8W-63Component Page
Driver Heated Seat Switch.............. 8W-63
Driver Lumbar Motor.................. 8W-63
Driver Power Seat Front Vertical Motor.... 8W-63
Driver Power Seat Horizontal Motor....... 8W-63
Driver Power Seat Rear Vertical Motor..... 8W-63
Driver Power Seat Switch............... 8W-63
Driver Power Window Motor............. 8W-60
Electric Brake Provision................ 8W-54
Engine Control Module................. 8W-30
Engine Coolant Temperature Sensor....... 8W-30
Engine Oil Pressure Sensor.............. 8W-30
Engine Starter Motor Relay.............. 8W-21
Engine Starter Motor................... 8W-21
EVAP/Purge Solenoid................... 8W-30
Fender Lamp......................... 8W-51
Fog Lamp Relay....................... 8W-50
Fog Lamp............................ 8W-50
Fuel Heater Relay..................... 8W-30
Fuel Heater........................ 8W-30-36
Fuel Injection Pump................... 8W-30
Fuel Injectors......................... 8W-30
Fuel Pump Module.................... 8W-30
Fuel Pump Relay...................... 8W-30
Fuel Tank Module..................... 8W-30
Fuel Transfer Pump.................... 8W-30
Fuses (JB)........................... 8W-12
Fuses (PDC).......................... 8W-10
Fusible Link....................... 8W-20, 30
Grounds............................. 8W-15
Generator............................ 8W-20
Glove Box Lamp And Switch............. 8W-44
Headlamp Beam Select Switch........... 8W-50
Headlamp Switch...................... 8W-50
Headlamp........................... 8W-50
Heated Mirror Relay................... 8W-62
Heated Mirror Switch.................. 8W-62
Heated Seat Relay..................... 8W-12
High Note Horn....................... 8W-41
Horn Relay.......................... 8W-41
Horn Switch.......................... 8W-41
Idle Air Control Motor.................. 8W-30
Ignition Coils......................... 8W-30
Ignition Switch....................... 8W-10
Instrument Cluster.................... 8W-40
Intake Air Heater Relays................ 8W-30
Intake Air Heater..................... 8W-30
Intake Air Temperature Sensor........... 8W-30
Intermittent Wiper Switch............... 8W-53
Joint Connectors....... 8W-10, 12, 15, 30, 34, 35,
40, 44, 45, 51, 53, 54, 70
Junction Block........................ 8W-12
Leak Detection Pump.................. 8W-30
BR/BE8W-02 COMPONENT INDEX 8W - 02 - 1

8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Clutch................ 8W-10-27
A/C Compressor Clutch Relay......... 8W-10-9, 27
Aftermarket Center High Mounted Stop
Lamp........................... 8W-10-13
Aftermarket Trailer Tow Connector....... 8W-10-21
Automatic Shut Down Relay.......... 8W-10-14, 20
Auxiliary Battery..................... 8W-10-8
Battery............................. 8W-10-8
Blower Motor....................... 8W-10-23
Blower Motor Relay................. 8W-10-8, 23
Brake Lamp Switch................. 8W-10-8, 13
Capacitor.......................... 8W-10-16
Center High Mounted Stop Lamp No. 1.... 8W-10-13
Center High Mounted Stop Lamp No. 2.... 8W-10-13
Central Timer Module.............. 8W-10-22, 26
Circuit Breaker 2.................... 8W-10-10
Clockspring......................... 8W-10-26
Combination Flasher.................. 8W-10-13
Controller Antilock Brake.............. 8W-10-23
Daytime Running Lamp Module......... 8W-10-25
Electric Brake Provision............. 8W-10-13, 21
Engine Control Module................ 8W-10-12
Engine Starter Motor................. 8W-10-23
Engine Starter Motor Relay........... 8W-10-8, 23
Fog Lamp Relay..................... 8W-10-25
Fuel Heater........................ 8W-10-20
Fuel Heater Relay.................. 8W-10-8, 20
Fuel Injection Pump.................. 8W-10-12
Fuel Injector No. 1................. 8W-10-15, 16
Fuel Injector No. 2................. 8W-10-15, 16
Fuel Injector No. 3................. 8W-10-15, 16
Fuel Injector No. 4................. 8W-10-15, 16
Fuel Injector No. 5................. 8W-10-15, 16
Fuel Injector No. 6................. 8W-10-15, 16
Fuel Injector No. 7................. 8W-10-15, 16
Fuel Injector No. 8................. 8W-10-15, 16
Fuel Injector No. 9................... 8W-10-16
Fuel Injector No. 10................... 8W-10-16
Fuel Pump Module................... 8W-10-11
Fuel Pump Relay.................. 8W-10-11, 12
Fuse 1 (JB)......................... 8W-10-10
Fuse 1 (PDC)...................... 8W-10-8, 10
Fuse 2 (PDC)................... 8W-10-8, 10, 22
Fuse 3 (PDC)................... 8W-10-8, 11, 12
Fuse 4 (JB)......................... 8W-10-10
Fuse 4 (PDC)...................... 8W-10-8, 13
Fuse 5 (PDC)...................... 8W-10-8, 13
Fuse 6 (PDC)................... 8W-10-8, 14, 20
Fuse 7 (PDC)...................... 8W-10-8, 20
Fuse 8 (PDC)...................... 8W-10-8, 21
Fuse 9 (PDC)...................... 8W-10-8, 23
Fuse 10 (PDC)..................... 8W-10-8, 22
Fuse 11 (PDC)..................... 8W-10-8, 23
Fuse 12 (JB)........................ 8W-10-10
Fuse 12 (PDC)................... 8W-10-8, 9, 23
Fuse 13 (JB)........................ 8W-10-10
Component Page
Fuse 14 (JB)........................ 8W-10-10
Fuse B (PDC)................... 8W-10-8, 9, 24
Fuse C (PDC)..................... 8W-10-9, 24
Fuse E (PDC)..................... 8W-10-9, 24
Fuse F (PDC)..................... 8W-10-9, 24
Fuse G (PDC)..................... 8W-10-9, 25
Fuse H (PDC)..................... 8W-10-9, 26
Fuse I (PDC)...................... 8W-10-9, 26
Fuse J (PDC)...................... 8W-10-9, 27
Fuse K (PDC)............. 8W-10-9, 14, 17, 18, 19
Fuse L (PDC)..................... 8W-10-9, 27
Fuse Gen (PDC)................... 8W-10-8, 27
G201............................. 8W-10-22
Generator........................ 8W-10-8, 27
Headlamp Beam Select Switch........... 8W-10-25
Headlamp Switch.................. 8W-10-9, 24
High Note Horn..................... 8W-10-26
Horn Relay....................... 8W-10-9, 26
Ignition Coil........................ 8W-10-15
Ignition Coil 4 Pack................... 8W-10-16
Ignition Coil 6 Pack................... 8W-10-16
Ignition Switch................. 8W-10-8, 10, 22
Joint Connector No. 1.............. 8W-10-25, 26
Joint Connector No. 2........ 8W-10-8, 9, 11, 12, 14,
15, 16, 20, 21
Joint Connector No. 5................. 8W-10-22
Joint Connector No. 6............ 8W-10-13, 22, 26
Joint Connector No. 8................. 8W-10-22
Junction Block.................. 8W-10-8, 10, 13
Left Fog Lamp...................... 8W-10-25
Left Headlamp...................... 8W-10-24
Left Outboard Headlamp.......... 8W-10-9, 24, 25
Low Note Horn...................... 8W-10-26
Oxygen Sensor 1/1 Left Bank Up . . . 8W-10-17, 18, 19
Oxygen Sensor 1/1 Upstream............ 8W-10-17
Oxygen Sensor 1/2 Downstream.......... 8W-10-17
Oxygen Sensor 1/2 Left Bank Down....... 8W-10-19
Oxygen Sensor 1/2 Pre-Catalyst.......... 8W-10-18
Oxygen Sensor 1/3 Post-Catalyst......... 8W-10-18
Oxygen Sensor 2/1 Right Bank Up . . 8W-10-17, 18, 19
Oxygen Sensor 2/2 Right Bank Down...... 8W-10-19
Oxygen Sensor Downstream Relay..... 8W-10-18, 19
Power Distribution Center.... 8W-10-8, 9, 10, 11, 12,
13, 14, 2, 20, 21, 22, 23, 24, 25, 26, 27
Power Outlet...................... 8W-10-9, 27
Powertrain Control Module . . 8W-10-11, 12, 15, 16, 20
Quad High Beam Relay................ 8W-10-24
Right Fog Lamp..................... 8W-10-25
Right Headlamp..................... 8W-10-24
Right Outboard Headlamp......... 8W-10-9, 24, 25
Security Relay..................... 8W-10-9, 25
Trailer Tow Connector................. 8W-10-21
Trailer Tow Relay.................... 8W-10-21
Transmission Control Relay........... 8W-10-9, 26
Transmission Solenoid Assembly......... 8W-10-26
Turn Signal/Hazard Switch............. 8W-10-13
BR/BE8W-10 POWER DISTRIBUTION 8W - 10 - 1

8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Clutch Relay.... 8W-30-14, 38, 39
A/C High Pressure Switch.......... 8W-30-14, 39
A/C Low Pressure Switch.......... 8W-30-14, 39
A/C-Heater Control............... 8W-30-14, 39
Accelerator Pedal Position Sensor....... 8W-30-30
Airbag Control Module............ 8W-30-15, 40
Automatic Shut Down Relay..... 8W-30-3, 17, 18,
19, 22, 23, 24, 25, 26, 27, 28
Battery........................... 8W-30-35
Battery Temperature Sensor............ 8W-30-4
Brake Lamp Switch.............. 8W-30-8, 7, 37
Camshaft Position Sensor........... 8W-30-5, 32
Capacitor......................... 8W-30-28
Central Timer Module............. 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
Daytime Running Lamp Module........ 8W-30-38
Engine Control Module . . 8W-30-3, 7, 29, 30, 31, 32,
33, 34, 35, 36, 37, 38, 39, 40, 41
Engine Coolant Temperature Sensor . . . 8W-30-9, 34
Engine Oil Pressure Sensor......... 8W-30-13, 33
EVAP/Purge Solenoid................ 8W-30-13
Fuel Heater........................ 8W-30-36
Fuel Heater Relay................... 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, 20, 22
Fusible Link....................... 8W-30-35
G100............................. 8W-30-12
G102.......................... 8W-30-36, 37Component Page
G105..................... 8W-30-2, 16, 20, 21
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....................... 8W-30-25
Ignition Coil 4 Pack................. 8W-30-28
Ignition Coil 6 Pack................. 8W-30-28
Instrument Cluster............ 8W-30-15, 34, 40
Intake Air Heater................... 8W-30-35
Intake Air Heater Relay No. 1......... 8W-30-35
Intake Air Heater Relay No. 2......... 8W-30-35
Intake Air Temperature Sensor...... 8W-30-10, 32
Joint Connector No. 1....... 8W-30-4, 7, 8, 12, 36,
37, 38, 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, 33
Output Speed Sensor................. 8W-30-5
Overdrive Switch.................... 8W-30-6
Overhead Console................ 8W-30-15, 40
Oxygen Sensor 1/1 Left Bank Up.... 8W-30-18, 20,
21, 22
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, 20,
21, 22
Oxygen Sensor 2/2 Right Bank Down.... 8W-30-20
Oxygen Sensor Downstream Relay . . . 8W-30-19, 21
Park/Neutral Position Switch....... 8W-30-13, 38
Power Distribution Center . . 8W-30-2, 3, 11, 17, 18,
19, 22, 23, 24, 25, 26, 27, 28, 29, 36, 37
Powertrain Control Module . . 8W-30-2, 3, 4, 5, 6, 7,
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

(5) After honing, it is necessary that the block be
cleaned to remove all traces of abrasive. Use a brush
to wash parts with a solution of hot water and deter-
gent. Dry parts thoroughly. Use a clean, white, lint-
free cloth to check that the bore is clean. Oil the
bores after cleaning to prevent rusting.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Recover refrigerant from a/c system, if
equipped (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(4) Remove the a/c condenser, if equipped (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - REMOVAL).
(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/TRANS-
AXLE/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.
Fig. 3 Cylinder Bore Crosshatch Pattern
1 - CROSSHATCH PATTERN
2 - INTERSECT ANGLE
9 - 12 ENGINE 5.9LBR/BE
ENGINE 5.9L (Continued)

(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/TRANS-
AXLE/MANUAL/SHIFT COVER - INSTALLATION).
(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).
(21) Using a new gasket, install throttle body
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE BODY - INSTALLATION).
(22) Connect the throttle linkage (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - INSTALLATION).
(23) Install the air cleaner resonator and duct
work..
(24) Install the generator and wire connections
(Refer to 8 - ELECTRICAL/CHARGING/GENERA-
TOR - INSTALLATION).
(25) Install a/c compressor and lines (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - INSTALLATION).(26) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(27) Install upper radiator support crossmember.
(28) Install radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - INSTALLATION).
(29) Connect the radiator lower hose.
(30) Connect the transmission oil cooler lines to
the radiator.
(31) Install the fan shroud.
(32) Install the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
(33) Connect the radiator upper hose.
(34) Install the washer bottle.
(35) Install the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
INSTALLATION).
(36) Connect the transmission cooler lines.
(37) If equipped, install the condenser (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - INSTALLATION).
(38) Evacuate and charge the air conditioning sys-
tem, if equipped (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE).
(39) Add engine oil to crankcase (Refer to LUBRI-
CATION & MAINTENANCE/FLUID TYPES - SPEC-
IFICATIONS).
(40) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(41) Connect battery negative cable.
(42) Start engine and inspect for leaks.
(43) Road test vehicle.
SPECIFICATIONS
5.9L ENGINE
ENGINE SPECIFICATIONS
DESCRIPTION SPECIFICATION
GENERAL SPECIFICATIONS
Engine Type 90É V-8 OHV
Bore and Stroke 101.6 x 90.9 mm
(4.00 x 3.58 in.)
Displacement 5.9L (360 c.i.)
Compression Ratio 9.1:1
Firing Order 1±8±4±3±6±5±7±2
Lubrication Pressure Feed ± Full
Flow
BR/BEENGINE 5.9L 9 - 13
ENGINE 5.9L (Continued)

OPERATION
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.
OPERATION - CYLINDER 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.
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
(1) Disconnect the battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the air cleaner resonator and duct
work.
(4) Remove the intake manifold-to-generator
bracket support rod. Remove the generator.
(5) Remove closed crankcase ventilation system.
(6) Disconnect the evaporation control system.
(7) Perform the Fuel System Pressure Release pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY - STANDARD PROCEDURE). Disconnect the
fuel supply line (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(8) Disconnect accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(9) Remove distributor cap and wires.
(10) Disconnect the coil wires.
(11) Disconnect heat indicator sending unit wire.
(12) Disconnect heater hoses and bypass hose.
(13) Remove cylinder head covers and gaskets
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(14) Remove intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL) and throttle body as an assembly. Dis-
card the flange side gaskets and the front and rear
cross-over gaskets.
BR/BEENGINE 5.9L 9 - 21
CYLINDER HEAD (Continued)

(15) Remove exhaust manifolds (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
REMOVAL).
(16) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations.
(17) Remove the head bolts from each cylinder
head and remove cylinder heads. Discard the cylin-
der head gasket.
(18) 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/mm (0.0001in/in.) 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
(1) Clean all surfaces of cylinder block and cylin-
der heads.
(2) Clean cylinder block front and rear gasket sur-
faces using a suitable solvent.
(3) Position new cylinder head gaskets onto the
cylinder block.
(4) Position cylinder heads onto head gaskets and
cylinder block.
(5) Starting at top center, tighten all cylinder head
bolts, in sequence (Fig. 6).
CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
TDC. Contact between the valves and piston could
occur.
(6) Install push rods and rocker arm assemblies in
their original position. Tighten the bolts to 28 N´m
(21 ft. lbs.) torque.
(7) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION) and throttle body assembly.
(8) Install exhaust manifolds (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
INSTALLATION).(9) If required, adjust spark plugs to specifications.
Install the plugs and tighten to 41 N´m (30 ft. lbs.)
torque.
(10) Install coil wire.
(11) Connect heat indicator sending unit wire.
(12) Connect the heater hoses and bypass hose.
(13) Install distributor cap and wires.
(14) Connect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(15) Install the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(16) Install the generator and drive belt (Refer to 7
- COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION). Tighten generator mounting bolt
to 41 N´m (30 ft. lbs.) torque. Tighten the adjusting
strap bolt to 23 N´m (200 in. lbs.) torque.
(17) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts.
(18) Place the cylinder head cover gaskets in posi-
tion and install cylinder head covers (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(19) Install closed crankcase ventilation system.
(20) Connect the evaporation control system.
(21) Install the air cleaner.
(22) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(23) Connect the negative cable to the battery.
(24) Start engine check for leaks.
Fig. 6 Cylinder Head Bolt Tightening Sequence
9 - 22 ENGINE 5.9LBR/BE
CYLINDER HEAD (Continued)