Dodge ram truck 3500 1996 Service Manual page 1056

9 - 66 5.2L ENGINE
REMOVAL AND I N S T A L L A T I O N (Continued)
(3) Remove the upper crossmember and top core
support.
(4) Remove the transmission oil cooler.
(5) Discharge the air conditioning system, i f
equipped (refer to Group 24, Heating and Air Condi­
tioning for service procedures).
(6) Remove the serpentine belt (refer to Group 7,
Cooling System).
(7) Remove the A/C compressor with the lines
attached. Set aside.
(8) I f equipped, remove the condenser.
(9) Remove the washer bottle.
(10) Disconnect the top radiator hose.
(11) Remove the fan.
(12) Remove the fan shroud.
(13) Disconnect the lower radiator hose.
(14) Remove radiator (refer to Group 7, Cooling
System).
(15) Remove the generator with the wire connec­
tions (refer to Group 8B, Battery/Starter/Generator
Service).
(16) Remove the air cleaner box.
(17) Disconnect the throttle linkage.
(18) Remove throttle body.
(19) Remove the intake manifold (refer to Group
11, Exhaust System and Intake Manifold).
(20) Remove the distributor cap and wiring.
(21) Disconnect the heater hoses.
(22) Disconnect the power steering hoses, i f
equipped.
(23) Disconnect the transmission cooler lines.
(24) Perform the Fuel System Pressure Release
procedure (refer to Group 14, Fuel System).
(25) Disconnect the fuel lines.
(26) On Manual Transmission vehicles, remove the
shift lever (refer to Group 21, Transmissions).
(27) Raise and support the vehicle on a hoist.
(28) Remove the drain plug and drain the engine
oil.
(29) Remove engine front mount thru-bolt nuts.
(30) Remove the transmission cooler line brackets
from oil pan.
(31) Disconnect exhaust pipe at manifold.
(32) Disconnect the starter wires. Remove starter
motor (refer to Group 8B, Battery/Starter/Generator
Service).
(33) Remove the dust shield and transmission
cover.
(34) Refer to group 21, Transmissions for trans­
mission removal.
(35) Remove the prop shaft (refer to Group 16,
Propeller Shaft).
(36) Lower the vehicle.
CAUTION: D O NOT lift the engine by the intake
manifold.
(37) Install an engine lifting fixture.
(38) 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 an engine support fixture.
(3) Raise and support the vehicle on a hoist.
(4) Refer to Group, 21 Transmissions for transmis­
sion installation
(5) Install rear transmission support.
(6) Install the prop shaft (refer to Group 16, Pro­
peller Shaft).
(7) Install the dust shield and transmission cover.
(8) Install the starter and connect the starter
wires (refer to Group 8B, Battery/Starter/Generator
Service).
(9) Install exhaust pipe to manifold.
(10) Install the transmission cooler line brackets
from oil pan.
(11) Install engine front mount thru-bolt nuts.
Tighten the nuts.
(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 Group 21, Transmissions).
(16) Connect the fuel lines.
(17) Connect the transmission cooler lines.
(18) Connect the power steering hoses, i f equipped.
(19) Connect the heater hoses.
(20) Install the distributor cap and wiring.
(21) Install the intake manifold (refer to Group 11,
Exhaust System and Intake Manifold).
(22) Using a new gasket, install throttle body.
Tighten the throttle body bolts to 23 N-m (200 in.
lbs.) torque.
(23) Connect the throttle linkage.
(24) Install the air cleaner box.
(25) Install the generator and wire connections
(refer to Group 8B, Battery/Starter/Generator Ser­
vice).
(26) Install radiator (refer to Group 7, Cooling Sys­
tem).
(27) Connect the lower radiator hose.
(28) Install the fan shroud.
(29) Install the fan.
(30) Connect the top radiator hose.
(31) Install the washer bottle.
(32) I f equipped, install the condenser.
(33) Install the A/C compressor with the lines
attached.
(34) Install the serpentine belt (refer to Group 7,
Cooling System).