Dodge ram truck 3500 1996 Service Manual page 1125

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• 8.0L ENGINE S - 135
R E M O V A L A N D I N S T A L L A T I O N (Continued)
(32) Refer to Group 21, Transmissions for trans­
mission removal.
(33) Lower vehicle.
CAUTION: DO NOT lift the engine by the intake
manifold.
(34) Install an engine lifting fixture.
(35) 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 the prop shaft (refer to Group 16, Pro­
peller Shaft).
(6) Install the starter and connect the starter
wires (refer to Group 8B, Battery/Starter/Generator
Service).
(7) Install exhaust pipe to manifold (refer to Group
11, Exhaust System and Intake Manifold).
(8) Install the transmission cooler line brackets
from oil pan.
(9) Tighten the Front mount thru-bolts and nuts to
102N*m (75 ft. lbs.).
(10) Install the drain plug and tighten to 34 N-m
(25 ft. lbs.) torque.
(11) Prime oil pump by squirting oil in the oil filter
mounting hole and filling the J-trap of the front tim­
ing cover. When oil is running out, install oil filter
that has been filled with oil.
(12) Lower the vehicle.
(13) Remove engine lifting fixture.
(14) On Manual Transmission vehicles, install the
shift lever (refer to Group 21, Transmissions).
(15) Connect the fuel lines.
(16) Connect the heater hoses.
(17) Install the upper intake manifold (refer to
Group 11, Exhaust System and Intake Manifold).
(18) Install the coil assemblies with the ignition
cables.
(19) Using a new gasket, install throttle body.
Tighten the throttle body nuts to 23 N-m (200 in.
lbs.) torque.
(20) Connect the throttle linkage.
(21) Install the air cleaner box.
(22) Install the generator and wire connections
(refer to Group 8B, Battery/Starter/Generator Ser­
vice).
(23) Install the upper crossmember.
(24) Install radiator (refer to Group 7, Cooling Sys­
tem).
(25) Connect the lower radiator hose.
(26) Install the transmission oil cooler.
(27) Connect the transmission cooler lines.
(28) Connect the power steering hoses, i f equipped.
(29) Install the fan shroud.
(30) Install the fan.
(31) Connect the top radiator hose.
(32) Install the washer bottle.
(33) I f equipped, install the condenser.
(34) Install the A/C compressor with the lines
attached.
(35) Install the serpentine belt (refer to Group 7,
Cooling System).
(36) Evacuate and charge the air conditioning sys­
tem, i f equipped (refer to Group 24, Heating and Air
Conditioning for service procedures).
(37) Add coolant to the cooling system (refer to
Group 7, Cooling System for the proper procedure).
(38) Install the battery.
(39) Warm engine and adjust.
(40) Road test vehicle.
CYLINDER HEAD COVER
Die-cast magnesium cylinder head covers (Fig. 15)
reduce noise and provide a good sealing surface. A
steel backed silicon gasket is used with the cylinder
head cover (Fig. 16).
Fig. 15 Cylinder Head Covers