Chrysler Full-Size Trucks 1989-1996 Repair Guide

Engine

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REMOVAL & INSTALLATION



Gasoline Engine
EXCEPT DAKOTA

See Figures 1, 2, 3, 4, 5, 6, 7 and 8

  1. Scribe hood hinge outlines on the hood and remove the hood from the vehicle. Disconnect the battery.
  2.  
  3. Drain the coolant from the radiator and engine block.
  4.  
  5. Drain the engine oil.
  6.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container.

  1. Remove the air cleaner.
  2.  
  3. Remove the starter.
  4.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Depressurize the fuel injection system.
  2.  
  3. Have the air conditioning refrigerant properly discharged at a reputable repair shop.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the rear engine mounts-1989-93 2WD V8 Ram

  1. If equipped, remove the transmission oil cooler.
  2.  
  3. Disconnect both radiator and heater hoses. Remove the radiator and set the fan shroud aside.
  4.  
  5. Remove the power steering pump and air pump with the hoses attached and lay them aside.
  6.  
  7. Remove the washer bottle.
  8.  
  9. Disconnect and tag the vacuum lines.
  10.  
  11. Remove the A/C compressor and lay it aside with the hoses connected, if enough slack exists. If not, disconnect the A/C hoses.
  12.  
  13. On manual transmission models, remove the shift lever.
  14.  
  15. Disconnect the throttle linkage and all electrical connection to the engine sensors. Tag all electrical connections before disconnecting.
  16.  
  17. Remove the alternator, fan, pulley and drive belt(s).
  18.  
  19. Remove the distributor cap and wires.
  20.  
  21. Remove and plug the fuel line.
  22.  
  23. Disconnect the exhaust pipe at the manifold.
  24.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the rear engine mounts-1989-93 4WD V8 Ram

  1. On automatic transmission models, remove the bell housing bolts and inspection plate. Attach a C-clamp on the front bottom of the transmission torque converter housing to prevent the torque converter from coming out.
  2.  
  3. Remove the retaining bolts from the torque converter drive plate. Mark the converter and drive plate to aid in reassembly.
  4.  
  5. Remove the driveshaft and engine rear support.
  6.  
  7. Support the transmission with a suitable transmission jack.
  8.  
  9. Remove the transmission.
  10.  
  11. Raise the rear of the engine approximately 2 in. (51mm) and remove the clutch or drive plate and the flywheel.
  12.  
  13. Using a boom hoist attached to the engine with the shortest hook-up possible, take up all tension and support the engine.
  14.  


WARNING
Do not lift the engine by the intake manifold.

  1. Remove the engine front mounts and insulators.
  2.  



Click image to see an enlarged view

Fig. Fig. 3: Exploded view of the rear engine mounts-1989-93 V6 Ram



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Fig. Fig. 4: Exploded view of the front engine mounts-1989-93 4WD V8 Ram



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Fig. Fig. 5: Exploded view of the front engine mounts-1989-93 V6 Ram

  1. Carefully remove the engine from the vehicle. Lift slowly and watch for any snagged or missed connections. Mount the engine on a suitable engine stand for further disassembly or service work.
  2.  

To install:
  1. Carefully lower the engine into the vehicle.
  2.  
  3. Install the engine front mounts and insulators.
  4.  



Click image to see an enlarged view

Fig. Fig. 6: Exploded view of the front engine mounts-all 1994-96 Ram models



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Fig. Fig. 7: Positioning the front engine mounts-all 1994-96 Ram models

  1. Raise the vehicle.
  2.  
  3. Install the torque converter drive plate bolts.
  4.  
  5. Install the clutch or drive plate and the flywheel.
  6.  
  7. If equipped with an automatic transmission, install the transmission intact with the torque converter. Use the match marks to align the drive plate and torque converter mounting bolts.
  8.  
  9. Install the insulator on the bottom face of the transmission housing. Install the driveshaft and engine rear support.
  10.  



Click image to see an enlarged view

Fig. Fig. 8: Various rear engine support cushion assemblies-all 1994-96 Ram models

  1. Install the distributor cap and wires.
  2.  
  3. Reconnect the fuel line.
  4.  
  5. Install the alternator, fan, pulley and drive belt(s).
  6.  
  7. On manual transmission models, install the transmission shift lever.
  8.  
  9. Connect the throttle linkage, heater and vacuum hoses and all electrical connections to the ignition, alternator, and all other electrical connections.
  10.  
  11. Install the A/C compressor with lines attached.
  12.  
  13. Install the power steering and air pumps.
  14.  
  15. Install the radiator and fan shroud.
  16.  
  17. Connect both radiator and heater hoses.
  18.  
  19. If equipped, install the transmission oil cooler.
  20.  
  21. Install the starter.
  22.  
  23. Install the air cleaner.
  24.  
  25. Fill the crankcase with engine oil.
  26.  
  27. On the V10 engine, prime the oil pump by filling the J-trap of the front timing cover with oil and quickly installing an oil-filled filter in place just as the oil is pouring out of the J-trap.
  28.  
  29. Fill the cooling system.
  30.  
  31. Connect the battery.
  32.  
  33. Check all fluid levels and perform all tune-up adjustments if the engine was rebuilt.
  34.  
  35. Take the vehicle back to the air conditioning service facility and have them properly evacuate and charge the air conditioning system.
  36.  

DAKOTA

See Figures 9, 10, 11, 12, 13, 14 and 15

  1. Relieve the fuel system pressure as described in Routine Maintenance .
  2.  
  3. Disconnect the negative battery cable from the battery and from the engine.
  4.  
  5. Scribe hood hinge outlines on the hood and remove the hood from the vehicle. Remove the hood and the oil dipstick.
  6.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Raise the vehicle and support safely, Drain the engine oil and coolant. Remove the lower radiator hose.
  2.  
  3. Remove the starter. Remove the engine to transmission struts, if equipped.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container.

  1. Remove the exhaust pipe from the exhaust manifold(s).
  2.  



Click image to see an enlarged view

Fig. Fig. 9: Exploded view of the engine mounts-1989-93 2.5L Dakota

  1. If the vehicle is equipped with a manual transmission, remove the transmission and all related parts.
  2.  
  3. If the vehicle is equipped with an automatic transmission, remove the inspection plate, matchmark the flexplate to the converter, remove the torque converter bolts and push the torque converter backwards as far as it will go.
  4.  
  5. Remove the engine mount lower nuts.
  6.  



Click image to see an enlarged view

Fig. Fig. 10: Exploded view of the right front engine mounts-1989-93 2WD V6 Dakota (V8 models similar)



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Fig. Fig. 11: Exploded view of the left front engine mounts-1989-93 2WD V6 Dakota (V8 models similar)

  1. If the vehicle is equipped with 4WD:
    1. On the left side, remove the two bolts attaching the bracket to the transmission bell housing and two brackets to pinion nose adaptor bolts. Separate the engine from the insulator by removing the upper nut washer assembly and through-bolt from the engine support bracket.
    2.  
    3. On the right side, remove the two brackets to axle. Disconnect the housing bolts and one bracket-to-bell housing bolt. Separate the engine from the insulator by removing the upper nut/washer assembly and the through-bolt from the engine support bracket.
    4.  

  2.  



Click image to see an enlarged view

Fig. Fig. 12: Exploded view of the rear engine mounts-1989-93 2WD V6 Dakota



Click image to see an enlarged view

Fig. Fig. 13: Exploded view of the rear engine mounts-1989-93 4WD V6 Dakota



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Fig. Fig. 14: Engine/axle interconnect-1989-93 4WD V6 Dakota

  1. Disconnect and plug the rubber fuel inlet and return hoses from the fuel lines at the front of the vehicle. Lower the vehicle.
  2.  



Click image to see an enlarged view

Fig. Fig. 15: Engine/axle front mounts-1989-93 4WD V6 Dakota

  1. Remove the air cleaner assembly and disconnect all linkages and cables. On the 3.9L engine, remove the throttle body. Stuff a clean shop towel into the intake manifold opening to prevent foreign objects from entering.
  2.  
  3. Unbolt the air conditioning compressor from the engine and position it to the side without discharging the system or disconnecting the lines.
  4.  
  5. Remove the radiator and shroud. Remove the fan and all related parts.
  6.  
  7. Unbolt the power steering pump brackets from the engine and position it to the side.
  8.  
  9. Remove the alternator, air pump and all brackets. Disconnect the heater hoses.
  10.  
  11. Remove the distributor cap with all spark plug wires attached. Disconnect all remaining electrical connectors, vacuum hoses and check for any other items preventing engine removal.
  12.  
  13. Attach a hoist or similar engine removal device to the intake manifold or cylinder head.
  14.  
  15. If the vehicle is equipped with an automatic transmission, support the transmission with a floor jack, or equivalent. Remove the remaining bell housing bolts.
  16.  
  17. Remove the engine from the vehicle slowly and carefully.
  18.  

To install:
  1. Lower the engine into position and install the engine mount bolts on the 2.5L engine. Install the upper bell housing bolts. Remove the hoist or engine removal device. Install the oil dipstick.
  2.  
  3. Raise the vehicle and support it safely.
  4.  
  5. If the vehicle is equipped with a manual transmission, install the transmission and all related parts.
  6.  
  7. If the vehicle is equipped with an automatic transmission, align the torque converter and flexplate and install the bolts. Install the inspection plate, starter and the engine-to-transmission struts, if equipped.
  8.  
  9. Connect the rubber fuel inlet and return hoses to the fuel lines at the front of the vehicle.
  10.  
  11. Install the exhaust pipe to the exhaust manifold(s). Install the lower radiator hose. Lower the vehicle.
  12.  
  13. Connect the heater hoses.
  14.  
  15. Make sure the negative battery cable is not connected to the battery. Connect the engine side of the negative cable to the engine. Install the alternator, air pump, power steering pump and all brackets.
  16.  
  17. Install the air conditioning compressor.
  18.  
  19. Install the throttle body using a new base gasket and connect all linkages and cables. Connect all electrical connectors, vacuum hoses, etc. that were disconnected during the engine removal procedure.
  20.  
  21. Install the fan and all related parts. Adjust all belt tensions.
  22.  
  23. Install the radiator and shroud.
  24.  
  25. Install the distributor cap with all spark plug wires attached.
  26.  
  27. Install the air cleaner assembly.
  28.  
  29. Install the hood.
  30.  
  31. Fill the engine with the specified amount of oil and fill the radiator with coolant.
  32.  
  33. Connect the negative battery cable and set all adjustments to specifications.
  34.  

DIESEL ENGINE

See Figures 16, 17, 18, 19 and 20


CAUTION
This engine has a dry weight of 880 lbs. (400 kg). Make sure the engine removal equipment is rated adequately, or personal injury may result.

  1. Scribe hood hinge outlines on the hood and remove the hood from the vehicle.
  2.  
  3. Disconnect the negative cable from the battery and from the engine.
  4.  
  5. Drain the coolant.
  6.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container.

  1. Remove the radiator, shroud, belt, fan and all related parts.
  2.  
  3. Remove the intake and exhaust pipes from the turbocharger.
  4.  
  5. Disconnect the air conditioner connections. Cover the openings on the compressor.
  6.  
  7. Disconnect the alternator and all other electrical connection to the engine.
  8.  
  9. Disconnect the accelerator linkage.
  10.  
  11. Disconnect the throttle linkage from the control lever, but do not remove the control lever from the injection pump.
  12.  
  13. Disconnect all engine driven accessories.
  14.  
  15. Raise the vehicle and support safely. Remove the starter.
  16.  
  17. If equipped with automatic transmission, remove the torque converter bolts and remove the lower bell housing bolts. If equipped with manual transmission, remove the transmission.
  18.  
  19. Drain the oil from the engine.
  20.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.



Click image to see an enlarged view

Fig. Fig. 16: Details of the front engine mount-1989-93 diesel engines

  1. Disconnect the transmission oil cooler lines from their brackets, if equipped.
  2.  



Click image to see an enlarged view

Fig. Fig. 17: Exploded view of the rear diesel engine mount-1989-93 2WD models



Click image to see an enlarged view

Fig. Fig. 18: Exploded view of the rear diesel engine mount-1989-93 4WD models

  1. Disconnect the exhaust pipe from the turbocharger. Lower the vehicle.
  2.  
  3. Disconnect and plug the fuel lines.
  4.  



Click image to see an enlarged view

Fig. Fig. 19: Exploded view of the front engine mounts-1993-96 diesel engines

  1. Using the proper equipment, hoist the engine slightly using the lifting eyes and support the transmission, if still installed.
  2.  



Click image to see an enlarged view

Fig. Fig. 20: Position the front engine mounts as shown-1993-96 diesel engines

  1. Remove the motor mounts.
  2.  
  3. Remove the upper bell housing bolts.
  4.  
  5. Remove the engine from the vehicle.
  6.  

To install:
  1. Position the engine in the engine compartment and install the motor mounts. Tighten the nuts and bolts to 57 ft. lbs. (77 Nm).
  2.  
  3. Install the bell housing bolts and torque converter bolts, if equipped. Install the manual transmission, if equipped.
  4.  
  5. Install the starter.
  6.  
  7. Connect the exhaust pipe.
  8.  
  9. Connect the transmission oil cooler lines to their brackets, if equipped.
  10.  
  11. Connect the fuel lines.
  12.  
  13. Connect the power steering lines.
  14.  
  15. Connect all engine driven accessories.
  16.  
  17. Connect the accelerator linkage.
  18.  
  19. Connect the throttle linkage to the control lever.
  20.  
  21. Connect the air conditioner connections.
  22.  
  23. Connect the alternator and all other electrical connections to the engine.
  24.  
  25. Install the intake and exhaust pipes to the turbocharger.
  26.  
  27. Install the fan and all related parts, shroud and radiator.
  28.  
  29. Fill the engine with the proper amount of diesel engine oil.
  30.  
  31. Fill the radiator with coolant.
  32.  
  33. Connect the negative battery cable, set all adjustments to specifications and check for leaks.
  34.  

 
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