Chrysler RAM TRUCK 2500 1994 Service Manual page 768

(39) Remove engine from vehicle and install engine
assembly on a repair stand.
INSTALLATION
(1) Remove engine from the repair stand and posi­
tion i n 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) AUTOMATIC TRANSMISSION:
(a) Install transmission bolts.
(b) Install torque converter bolts. Tighten the
bolts to 31 N-m (270 i n . lbs.) torque.
(c) Remove the support from transmission.
(5) M A N U A L TRANSMISSION:
(a) Install flywheel and ring gear.
(b) Install clutch assembly.
(c) Install bell housing.
(d) Install transmission and bolts.
(e) Connect all wiring and connectors.
(f) Install clutch assembly and slave cylinder.
(g) Install the crossmember.
(h) Install rear transmission support.
(i) Remove support from transmission.
(j) Install the prop shaft (refer to Group 16, Pro­
peller Shaft).
(6) Install the dust shield and transmission cover.
(7) Install the starter and connect the starter wires
(refer to Group 8B, Battery/Starter/Generator Ser­
vice).
(8) Install exhaust pipe to manifold.
(9) Install the transmission cooler line brackets
from oil pan.
(10) Install engine front mount thru-bolt nuts.
Tighten the nuts.
(11) Install the drain plug and tighten to 34 N-m
(25 ft. lbs.) torque.
(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 transmission cooler lines.
(17) Connect the power steering hoses, i f equipped.
(18) Connect the heater hoses.
(19) Install the distributor cap and wiring.
(20) Install the intake manifold (refer to Group 11,
Exhaust System and Intake Manifold).
(21) Using a new gasket, install throttle body.
Tighten the throttle body bolts to 23 N-m (200 i n .
lbs.) torque.
(22) Connect the throttle linkage.
(23) Install the air cleaner box.
(24) Install the generator and wire connections (re­
fer to Group 8B, Battery/Starter/Generator Service).
(25) Install radiator (refer to Group 7, Cooling Sys­
tem).
(26) Connect the lower radiator hose.
(27) Install the fan shroud.
(28) Install the fan.
(29) Connect the top radiator hose.
(30) Install the radiator overflow bottle.
(31) Install the washer bottle.
(32) I f equipped, install the condenser.
(33) Install the A/C compressor with the lines at­
tached.
(34) Install the serpentine belt (refer to Group 7,
Cooling System).
(35) Evacuate and charge the air conditioning sys­
tem, i f equipped (refer to Group 24, Heating and Air
Conditioning for service procedures).
(36) Install the transmission oil cooler.
(37) Install the upper crossmember and top core
support.
(38) Add coolant to the cooling system (refer to
Group 7, Cooling System for the proper procedure).
(39) Install the battery.
(40) Warm engine and adjust.
(41) Road test vehicle.
CYLINDER HEAD COVER
A steel backed silicon gasket is used with the cyl­
inder head cover (Fig. 1). This gasket can be used
again.
CYLINDER HEAD
J9209-105
Fig. 1 Cylinder Head Cover Gasket
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Disconnect closed ventilation system and evap­
oration control system from cylinder head cover.
(3) Remove cylinder head cover and gasket. The
gasket may be used again.
CLEANING
Clean cylinder head cover gasket surface.
Clean head rail, i f necessary.
INSPECTION
Inspect cover for distortion and straighten, i f nec­
essary.
Check the gasket for use i n head cover installation.
I f damaged, use a new gasket.