2003 DODGE RAM transmission fluid

8W-80 CONNECTOR PIN-OUTS
Component Page
4WD Switch (Manual Transfer Case)..... 8W-80-5
A/C Compressor Clutch............... 8W-80-5
A/C Pressure Transducer.............. 8W-80-5
A/C Pressure Transducer (Diesel)........ 8W-80-5
A/C-Heater Control C1................ 8W-80-6
A/C-Heater Control C2................ 8W-80-6
Accelerator Pedal Position Sensor
(5.7L/Diesel M/T Normal Build)....... 8W-80-6
Adjustable Pedal Motor............... 8W-80-7
Adjustable Pedal Switch............... 8W-80-7
Airbag Control Module................ 8W-80-7
Airbag Control Module-Left Side Impact . . 8W-80-8
Airbag Control Module-Right Side Impact . 8W-80-8
Airbag-Driver Squib 1................ 8W-80-8
Airbag-Left Curtain Squib............. 8W-80-8
Airbag-Passenger Squib 1............. 8W-80-9
Airbag-Right Curtain Squib............ 8W-80-9
Ambient Temperature Sensor........... 8W-80-9
Amplifier Audio C1................... 8W-80-9
Amplifier Audio C2.................. 8W-80-10
Automatic Day/Night Mirror (Except
Base).......................... 8W-80-10
Backup Lamp Switch (3.7L/4.7L/5.7L/
8.0L)........................... 8W-80-10
Battery Temperature Sensor........... 8W-80-11
Blend Door Actuator (Single-Zone)...... 8W-80-11
Blower Motor...................... 8W-80-11
Blower Motor Resistor Block.......... 8W-80-11
Boost Pressure Sensor (Diesel)......... 8W-80-11
Brake Fluid Level Switch............. 8W-80-12
Brake Lamp Switch................. 8W-80-12
Brake Transmission Shift Interlock
Solenoid........................ 8W-80-12
C100 (Diesel)...................... 8W-80-12
C100 (Diesel)...................... 8W-80-13
C100 (Gas)........................ 8W-80-13
C100 (Gas)........................ 8W-80-13
C106 (5.7L)........................ 8W-80-14
C106 (5.7L)........................ 8W-80-14
C107 (5.7L)........................ 8W-80-15
C107 (5.7L)........................ 8W-80-15
C108 (Diesel)...................... 8W-80-15
C108 (Diesel)...................... 8W-80-16
C110 (Diesel)...................... 8W-80-16
C110 (Diesel)...................... 8W-80-16
C112 (Diesel)...................... 8W-80-17
C112 (Diesel)...................... 8W-80-17
C115 (Diesel)...................... 8W-80-17
C115 (Diesel)...................... 8W-80-17
C116 (Diesel)...................... 8W-80-17
C116 (Diesel)...................... 8W-80-18
C117 (Diesel)...................... 8W-80-18Component Page
C117 (Diesel)...................... 8W-80-18
C130............................. 8W-80-18
C130............................. 8W-80-20
C200............................. 8W-80-22
C200............................. 8W-80-22
C201............................. 8W-80-22
C201............................. 8W-80-23
C202............................. 8W-80-23
C202............................. 8W-80-23
C206............................. 8W-80-23
C206 (SLT+)....................... 8W-80-24
C216............................. 8W-80-24
C216............................. 8W-80-24
C217............................. 8W-80-24
C217............................. 8W-80-25
C218............................. 8W-80-25
C218............................. 8W-80-25
C219............................. 8W-80-26
C219............................. 8W-80-28
C220............................. 8W-80-29
C220............................. 8W-80-30
C301............................. 8W-80-30
C301............................. 8W-80-31
C302............................. 8W-80-31
C302............................. 8W-80-31
C304............................. 8W-80-32
C304............................. 8W-80-32
C305............................. 8W-80-32
C305............................. 8W-80-33
C306............................. 8W-80-33
C306............................. 8W-80-33
C307 (Tail Lamp Jumper)............. 8W-80-34
C307 (Tail Lamp Jumper)............. 8W-80-34
C308............................. 8W-80-34
C308............................. 8W-80-35
C309............................. 8W-80-35
C309............................. 8W-80-35
C310 (Tail Lamp Jumper)............. 8W-80-36
C310 (Tail Lamp Jumper)............. 8W-80-36
C311 (Except SLT+)................. 8W-80-36
C311 (Except SLT+)................. 8W-80-36
C312............................. 8W-80-37
C312............................. 8W-80-37
C313............................. 8W-80-37
C313............................. 8W-80-38
C314............................. 8W-80-38
C314............................. 8W-80-38
C315 (Heated/Power Seat)............ 8W-80-38
C315............................. 8W-80-39
C316............................. 8W-80-39
C316............................. 8W-80-39
C317............................. 8W-80-39
DR8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1

Component Page
Speaker-Right Instrument Panel....... 8W-80-97
Speaker-Right Rear................. 8W-80-97
Speed Control Servo................. 8W-80-97
Speed Control Switch-Left (ETC)....... 8W-80-98
Speed Control Switch-Left (Except ETC) . 8W-80-98
Speed Control Switch-Right (ETC)...... 8W-80-98
Speed Control Switch-Right (Except
ETC)........................... 8W-80-98
Switch-Driver Seat Belt.............. 8W-80-98
Switch-Passenger Airbag On-Off....... 8W-80-99
Tail/Stop/Turn Signal Lamp-Left....... 8W-80-99
Tail/Stop/Turn Signal Lamp-Right...... 8W-80-99
Tension Reducer-Seat Belt (Standard
Cab)........................... 8W-80-99
Tensioner-Left Seat Belt............. 8W-80-100
Tensioner-Right Seat Belt............ 8W-80-100
Throttle Position Sensor............. 8W-80-100
Throttle Position Sensor (Diesel)...... 8W-80-100
Trailer Tow Connector.............. 8W-80-101
Trailer Tow Connector-Add On........ 8W-80-101
Transfer Case Control Module C1...... 8W-80-101
Transfer Case Control Module C2...... 8W-80-102
Transfer Case Control Module C3...... 8W-80-102
Transfer Case Mode Sensor.......... 8W-80-102
Transfer Case Position Sensor (4.7L/
5.9L).......................... 8W-80-103
Transfer Case Selector Switch........ 8W-80-103
Transfer Case Shift Motor........... 8W-80-103
Transmission Control Module......... 8W-80-104Component Page
Transmission Range Sensor (5.9L/
Diesel)........................ 8W-80-105
Transmission Solenoid Assembly (5.9L/
8.0L).......................... 8W-80-105
Transmission Solenoid/Trs Assembly
(3.7L/4.7L/5.7L)................. 8W-80-106
Underhood Lamp.................. 8W-80-106
Vacuum Pump (Diesel).............. 8W-80-106
Vehicle Speed Sensor (Diesel)......... 8W-80-107
Vistronic Fan Drive (Diesel).......... 8W-80-107
Washer Fluid Level Switch........... 8W-80-107
Washer Pump Motor-Front........... 8W-80-107
Water In Fuel Sensor (Diesel)......... 8W-80-107
Wheel Speed Sensor-Left Front
(ABS)......................... 8W-80-108
Wheel Speed Sensor-Rear (ABS)....... 8W-80-108
Wheel Speed Sensor-Right Front
(ABS)......................... 8W-80-108
Wiper Motor-Front................. 8W-80-108
Washer Fluid Level Switch........... 8W-80-109
Washer Pump Motor-Front........... 8W-80-109
Water In Fuel Sensor (Diesel)......... 8W-80-109
Wheel Speed Sensor-Left Front
(ABS)......................... 8W-80-109
Wheel Speed Sensor-Rear (ABS)....... 8W-80-110
Wheel Speed Sensor-Right Front
(ABS)......................... 8W-80-110
Wiper Motor-Front................. 8W-80-110
8W - 80 - 4 8W-80 CONNECTOR PIN-OUTSDR

BRAKE FLUID LEVEL SWITCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 G9 20GY/BK BRAKE FLUID LEVEL SWITCH SENSE
2 Z231 20BK/DG GROUND
BRAKE LAMP SWITCH - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 A108 18TN/RD FUSED B(+)
2 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
3 V30 20DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT
3 V30 20DB/RD (NGC) FUSED IGNITION SWITCH (RUN-START)
4 V32 20YL/RD SPEED CONTROL SUPPLY
4 V32 20YL/RD (5.7L) BRAKE SWITCH NO. 2 SIGNAL
5 Z241 20BK/VT GROUND
6 K29 20WT/PK BRAKE SWITCH SENSE
6 K29 20WT/PK (NGC) BRAKE SWITCH NO. 1 SIGNAL
BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Y204 18OR/WT BTSI SOLENOID CONTROL
2 Z123 18BK/OR GROUND
C100 (DIESEL) - (DASH TO ENGINE)
CAV CIRCUIT
A K152 28WT
B B6 20WT/DB
C B7 20WT
D Z11 18BK/WT
E-
F Y1 18LG
G K4 18BK/LB
H Y169 18WT/TN
J Y168 18WT/LB
K Y3 18WT
L L60 18LG/TN
M L7 18BK/YL
N F15 20DB
P Y5 18OR
R-
S K154 18GY
8W - 80 - 12 8W-80 CONNECTOR PIN-OUTSDR

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Speed Control Switch-Right (ETC) WT At Steering Wheel N/S
Tail/Stop/Turn Signal Lamp-Left BK At Lamp N/S
Tail/Stop/Turn Signal Lamp-Right BK At Lamp N/S
Throttle Position Sensor NAT Throttle Body 4, 8
Trailer Tow Connector BK At Trailer Hitch 49
Trailer Tow Connector-Add On BK At Trailer Hitch 49, 51
Transfer Case Control Module C1 BK Left Side of Instrument Panel 37, 39
Transfer Case Control Module C2 GY Left Side of Instrument Panel 37, 39
Transfer Case Control Module C3 BK Left Side of Instrument Panel 37, 39
Transfer Case Mode Sensor BK Left Front Side of Transfer Case 20
Transfer Case Position Sensor BK Front Middle of Transfer Case 14, 15, 16, 20
Transfer Case Selector Switch BK Center of Instrument Panel 35, 37, 38
Transfer Case Shift Motor BK Left Rear of Transmission 20
Transmission Control Module BK Left Rear of Engine Compartment 21
Transmission Range Sensor BK Left side of Transmission 11, 12
Transmission Solenoid Assembly BK Left Side of Transmission 11, 12
Transmission Solenoid/TRS
Assembly (3.7L/4.7L)BK Left Side of Transmission 14, 15
Underhood Lamp BK Underside of Hood 31
Vistronic Fan Drive Front Engine Compartment 30
Washer Fluid Level Switch BK At Reservoir 25, 29, 30
Washer Pump Motor-Front BK At Washer Fluid Reservoir 25, 29, 30
Water In Fuel Sensor (Diesel) BK Right Side Engine 10
Wheel Speed Sensor-Left Front BK Left Rear Lower Side of Engine
Compartment26, 31
Wheel Speed Sensor-Rear BK Right Rear of Body 49
Wheel Speed Sensor-Right Front GY Right Rear Lower Side of Engine
Compartment25
Wiper Motor-Front BK Left Side of Cowl 26, 28
8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONDR
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

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.
Inspect valve springs. Replace as
necessary.
AIR ESCAPES THROUGH
TAILPIPEExhaust valve bent, burnt, or not
seated properlyInspect valve and valve seat.
Reface or replace, as necessary.
Inspect valve springs. 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
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repaired. Essen-
tially, this repair consists of:
²Drilling out worn or damaged threads.
²Tapping the hole with a special Heli-Coil Tap, or
equivalent.
²Installing an insert into the tapped hole to bring
the hole back to its original thread size.
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and MopartGasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN II
MopartEngine RTV GEN II is used to seal com-
ponents exposed to engine oil. This material is a spe-
cially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARtATF RTV
MopartATF RTV is a specifically designed black
silicone rubber RTV that retains adhesion and seal-
ing properties to seal components exposed to auto-
matic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKER
MopartGasket Maker is an anaerobic type gasket
material. The material cures in the absence of air
when squeezed between two metallic surfaces. It will
not cure if left in the uncovered tube. The anaerobic
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
DRENGINE - 3.7L 9 - 9
ENGINE - 3.7L (Continued)

DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either per-
formance (e.g., engine idles rough and stalls) or
mechanical (e.g., a strange noise).
(Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING)ÐPERFORMANCE and (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)ÐMECHANICAL for
possible causes and corrections of malfunctions.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
DIAGNOSIS AND TESTING) and (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION - DIAGNOSIS
AND TESTING) for the fuel system diagnosis.
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following diagnosis:
²Cylinder Compression Pressure Test (Refer to 9 -
ENGINE - DIAGNOSIS AND TESTING).
²Cylinder Combustion Pressure Leakage Test
(Refer to 9 - ENGINE - DIAGNOSIS AND TEST-
ING).
²Engine Cylinder Head Gasket Failure Diagnosis
(Refer to 9 - ENGINE/CYLINDER HEAD - DIAGNO-
SIS AND TESTING).
²Intake Manifold Leakage Diagnosis (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
DIAGNOSIS AND TESTING).
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repaired. Essen-
tially, this repair consists of:
²Drilling out worn or damaged threads.
²Tapping the hole with a special Heli-Coil Tap, or
equivalent.
²Installing an insert into the tapped hole to bring
the hole back to its original thread size.
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN II
MopartEngine RTV GEN II is used to seal com-
ponents exposed to engine oil. This material is a spe-
cially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARtATF RTV
MopartATF RTV is a specifically designed black
silicone rubber RTV that retains adhesion and seal-
ing properties to seal components exposed to auto-
matic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKER
MopartGasket Maker is an anaerobic type gasket
material. The material cures in the absence of air
when squeezed between two metallic surfaces. It will
not cure if left in the uncovered tube. The anaerobic
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 than using precut gas-
kets.
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
DRENGINE - 4.7L 9 - 93
ENGINE - 4.7L (Continued)

STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repaired. Essen-
tially, this repair consists of:
²Drilling out worn or damaged threads.
²Tapping the hole with a special Heli-Coil Tap, or
equivalent.
²Installing an insert into the tapped hole to bring
the hole back to its original thread size.
STANDARD PROCEDUREÐHYDROSTATIC
LOCK
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock
(regardless of what caused the problem), follow the
steps below.
(1) Perform the Fuel Pressure Release Procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(2) Disconnect the negative cable(s) from the bat-
tery.
(3) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(4) Place a shop towel around the spark plugs to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the spark plugs.
(5) With all spark plugs removed, rotate the crank-
shaft using a breaker bar and socket.
(6) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
(7) Be sure all fluid has been removed from the
cylinders.
(8) Repair engine or components as necessary to
prevent this problem from occurring again.
(9) Squirt a small amount of engine oil into the
cylinders to lubricate the walls. This will prevent
damage on restart.
(10) Install new spark plugs. Tighten the spark
plugs to 41 N´m (30 ft. lbs.) torque.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N´m (25 ft. lbs.) torque.
(13) Install a new oil filter.(14) Fill engine crankcase with the specified
amount and grade of oil. (Refer to LUBRICATION &
MAINTENANCE - SPECIFICATIONS).
(15) Connect the negative cable(s) to the battery.
(16) Start the engine and check for any leaks.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Remove the air cleaner resonator and duct
work as an assembly.
(3) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(4) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(5) Remove the viscous fan/drive (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(6) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(7) Remove the upper crossmember and top core
support.
NOTE: It is not necessary to drain A/C system for
engine removal.
(8) Remove the A/C compressor with the lines
attached. Secure compressor out of the way.
(9) Remove generator assembly (Refer to 8 -
ELECTRICAL/CHARGING/GENERATOR - REMOV-
AL).
(10) Perform the Fuel System Pressure Release
procedure (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY - STANDARD PROCEDURE).
(11) Remove the intake manifold and IAFM as an
assembly(Refer to 9 - ENGINE/MANIFOLDS/IN-
TAKE MANIFOLD - REMOVAL).
(12) Disconnect the heater hoses.
NOTE: It is not necessary to disconnect P/S hoses
from pump, for P/S pump removal.
(13) Remove the power steering pump and set
aside.
(14) Disconnect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(15) Raise and support the vehicle on a hoist and
drain the engine oil.
(16) Remove engine front mount thru-bolt nuts.
(17) Disconnect the transmission oil cooler lines
from their retainers at the oil pan bolts.
(18) Disconnect exhaust pipe at manifolds.
(19) Disconnect the starter wires. Remove starter
motor (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - REMOVAL).
9 - 186 ENGINE - 5.7LDR
ENGINE - 5.7L (Continued)

(20) Remove the structural dust cover and trans-
mission inspection cover,(Refer to 9 - ENGINE/EN-
GINE BLOCK/STRUCTURAL COVER - REMOVAL).
(21) Remove drive plate to converter bolts (Auto-
matic transmission equipped vehicles).
(22) Remove transmission bell housing to engine
block bolts.
(23) Lower the vehicle.
(24) Install engine lift fixture, special tool # 8984.
(25) Separate engine from transmission, remove
engine from vehicle, and install engine assembly on a
repair stand.
INSTALLATION
(1) Install engine lift fixture Special tool # 8984.
(2) Position the engine in the engine compartment.
(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) Position the thru-bolt into the support cushion
brackets.
(5) Lower engine assembly until engine mount
through bolts rest in mount perches.
(6) Install remaining transmission to engine block
mounting bolts and tighten.
(7) Tighten engine mount through bolts.
(8) Install drive plate to torque converter bolts.
(Automatic transmission models)
(9) Install the structural dust cover and transmis-
sion dust cover,(Refer to 9 - ENGINE/ENGINE
BLOCK/STRUCTURAL COVER - INSTALLATION) .
(10) Install the starter and connect the starter
wires (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(11) Install exhaust pipe to manifold.(12) Lower the vehicle.
(13) Remove engine lift fixture, special tool # 8984.
(14) Connect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(15) Reinstall the power steering pump.
(16) Connect the heater hoses.
(17) Install the intake manifold.
(18) Using a new gasket, install throttle body
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE BODY - INSTALLATION).
(19) Install the generator and wire connections
(Refer to 8 - ELECTRICAL/CHARGING/GENERA-
TOR - INSTALLATION).
(20) Install a/c compressor and lines (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - INSTALLATION).
(21) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(22) Install upper radiator support crossmember.
(23) Install radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - INSTALLATION).
(24) Connect the radiator lower hose.
(25) Connect the transmission oil cooler lines to
the radiator.
(26) Install the fan shroud.
(27) Install the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
(28) Connect the radiator upper hose.
(29) Install the washer bottle.
(30) Connect the transmission cooler lines.
(31) Install the air cleaner resonator and duct
work..
(32) Add engine oil to crankcase (Refer to LUBRI-
CATION & MAINTENANCE/FLUID TYPES - SPEC-
IFICATIONS).
(33) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(34) Connect battery negative cable.
(35) Start engine and inspect for leaks.
(36) Road test vehicle.
DRENGINE - 5.7L 9 - 187
ENGINE - 5.7L (Continued)