2003 Dodge RAM Standard Owners Manual

FRAMES & BUMPERS

13 - 5

(7) Make a vertical mark on the inside and outside face of the frame rail 112 mm (4.5 in.) from the for- ward edge of the PLP hole in the sides of the rail. (Fig. 8)

(8) Using a straightedge, connect the two lines on

the top and bottom of the rail.

(9) Using the service tip as a guide, re-check your cut lines to ensure the service tip will fit when the cut is made.

CAUTION: Do not use any flame or plasma cutting equipment to cut the frame in this procedure. This is due to the inaccurate nature of the cut-line and the fact that the high temperatures achieved during flame or plasma cutting will change the metal char- acteristics and may weaken the frame and/or repair location.

(10) Using a reciprocating saw or equivalent, care- fully cut and remove the damaged frame rail tip. (Fig. 7)

DR FRAME (Continued)

CAUTION: Do not reuse damaged fasteners, quality of repair would be suspect. Failure to use only pro- duction fasteners or fasteners of equivalent hard- ness can result in loosening or failure. Do not drill any holes in the frame that are not specifically out- lined in this or other, DaimlerChrysler procedure as frame rail failure can result. When using heat to straighten frame components do not exceed 566°C (1050°F), metal fatigue can result.

NOTE: Procedures for 4X2 and 4X4 are common except as noted in this procedure.

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the front wheelhouse splash shield. (Refer to 23 - BODY/EXTERIOR/FRONT WHEEL- HOUSE SPLASH SHIELD - REMOVAL)

(3) Remove the bolts and position aside the wire

harness and grounds, if required.

(4) Remove the front bumper.

(Refer to 13 - FRAME & BUMPERS/BUMPERS/FRONT BUMPER - REMOVAL)

(5) Loosen and lower the stabilizer bar mount and (Refer to 2 - SUSPENSION/FRONT/STABI-

bar. LIZER BAR - REMOVAL)

(6) Remove the front cab mount bolt to the Front

End Sheet Metal (FESM) bracket. (Fig. 6)

Fig.7FRAMECUTLOCATION

1 - REPAIR ROOT OPENING 2 - SERVICE SLEEVE 3 - PRINCIPLE LOCATING POINT (PLP) 4 - SUSPENSION BRACKETS 5 - FRAME 6 - FRAME CUTOFF LOCATION - 112 mm (4.5 in.) 7 - FRAME SERVICE TIP

Fig.6REPLACEMENTFRAMETIP

1 - FRONT END SHEET METAL (FESM) BRACKET 2 - CAB INSULATOR 3 - RING-FILLET WELD/HOLE 4 - PRINCIPLE LOCATING POINT (PLP) 5 - WELD ROOT GAP 4 mm - 6 mm (0.16 in. - 0.24 in.) 6 - FRONT CAB MOUNT BOLT 7 - REPLACEMENT FRAME TIP

FRAMES & BUMPERS

13 - 6
FRAME (Continued)

(11) Assemble the service sleeve. Refer to SER- VICE SLEEVE ASSEMBLY at the end of this proce- dure.

NOTE: Any burned surface coatings will need to be removed from the sleeve prior to installation and application of corrosion preventative coatings.

DR

(12) Smooth and square the cut edges of the origi-

nal frame. (Fig. 7)

(13) Dress the cut edge of the existing frame in

preparation for the new rail tip.

(a) Drill four 13 mm (0.5 in.) diameter holes in the new tip and four more in the existing frame to accommodate ring-fillet welds. Center these holes 19 mm (0.75 in.) from the cut face of the rail and 38 mm (1.5 in.) from the top and bottom of the rail. (Fig. 8)

(b) Bevel the edges of the new tip, existing frame, and ring-fillet holes 25° - 30°. Scribing a line 2 mm from the cut edge and then grinding back to the mark will simplify the bevel creation process and accuracy. (Fig. 9)

(c) Remove any burrs at the holes and beveled

edges.

Fig.9WELDDIMENSIONS

1 - FRAME REPLACEMENT TIP 2 - FRAME RAIL 3 - FRAME DRESS ANGLE 25°-30° 4 - ROOT PASS 5 - COVER PASS 6 - SERVICE SLEEVE 7 - WELD ROOT GAP 4 mm - 6 mm (0.16 in. - 0.24 in.) 8 - SERVICE SLEEVE

(14) Dry fit the new rail to ensure alignment and

fit and make any adjustments as necessary.

(15) Remove all internal and external OEM e-coat within 51 mm (2.0 in.) of the weld joint on the replacement tip and the existing frame rail.

NOTE: Any burned surface coatings will need to be removed prior to application of corrosion preventa- tive coatings.

CAUTION: Shield the surrounding area and compo- nents from exposure to the welding spatter and heat.

Fig.8REPAIRSLEEVEINSTALLATION(TYPICAL) 1 - REPLACEMENT FRAME TIP 2 - FRAME RAIL 3 - SERVICE SLEEVE 4 - CENTER LINE 5 - LOCATOR LINES (2) 6 - HORIZONTAL WELD HOLE LOCATION - 38 mm (1.5 in.)(BOTH FRAME SECTIONS) 7 - LOCATOR LINE DIMENSION - 2 mm (0.08 in.) 8 - VERTICAL WELD HOLE LOCATION - 19 mm (0.75 in.)(BOTH FRAME SECTIONS) 9 - RING FILLET WELD HOLES

DR FRAME (Continued)

FRAMES & BUMPERS

13 - 7

(16) On 4X4 models use the service sleeve as a template to drill a hole in the frame tip to accommo- date the sway bar mounting bolt. (Fig. 12)

(17) Slide the service sleeve into the replacement frame tip and align to the 2 mm (0.08 in.) off center line made previously during the sleeve assembly and tack the ring fillet welds to hold them in place. (Fig. 10) (Fig. 11) (Fig. 12) (Fig. 13)

(18) On 4X4 models, install the sway bar tapping plate and secure with tack welds. (Fig. 12) (Fig. 13)

Fig.104X2SLEEVEINSTALLATION

1 - REPLACEMENT FRAME TIP 2 - FRAME RAIL 3 - SERVICE SLEEVE 4 - PLP 5 - SWAY BAR MOUNTING BRACKET 6 - TAPPING PLATE 7 - ROOT WELD GAP

Fig.114X2SLEEVEINSTALLATION

1 - REPLACEMENT FRAME TIP 2 - ROOT WELD GAP 3 - SERVICE SLEEVE 4 - SWAY BAR MOUNTING BRACKET 5 - TAPPING PLATE

FRAMES & BUMPERS

13 - 8
FRAME (Continued)

DR

Fig.124X4TAPPINGPLATE/SLEEVE

INSTALLATION

1 - REPLACEMENT FRAME TIP 2 - FRAME RAIL 3 - SERVICE SLEEVE 4 - PLP 5 - SWAY BAR MOUNTING BRACKET 6 - TAPPING PLATE 7 - ROOT WELD GAP 8 - SLEEVE TAB

(19) Apply ring-fillet welds into the ring-fillet weld holes on the replacement frame tip, using the Weld Process Specifications table. (Fig. 14)

(20) Install the upper FESM insulator onto the replacement tip and position the service sleeve/re- placement tip into the existing frame rail.

(21) Loosely install the lower FESM insulator and

cab mounting bolt.

Fig.134X4TAPPINGPLATE/SLEEVEINSTALLATION 1 - REPLACEMENT FRAME TIP 2 - ROOT WELD GAP 3 - SERVICE SLEEVE 4 - SWAY BAR MOUNTING BRACKET 5 - TAPPING PLATE 6 - SLEEVE TAB

Fig.14RINGFILLETWELD

1 - WELD START LOCATION 2 - WELD END LOCATION 3 - RING-FILLET WELD

DR FRAME (Continued)

(22) Using the appropriate measuring equipment, verify the front end sheet metal bracket’s location in all three (X,Y, and Z) planes of space, and adjust if required. (Fig. 15)

FRAMES & BUMPERS

13 - 9

CAUTION: Shield the surrounding area and compo- nents from exposure to the welding spatter and heat.

(23) When correctly fitted and a weld root gap of 4
mm minimum to 6 mm maximum (0.16 in - 0.24 in) is established, tack the ring fillet welds to hold the tip in position, then complete the ring fillet welds.

NOTE: Ring-fillet welds may be filled in with weld material if an improved cosmetic appearance is desired.

(24) Confirm alignment of the replacement frame

rail tip. (Fig. 15)

(25) Final welding should be performed in a skip (stitch) type method to minimize the heat buildup and frame distortion, utilizing the Weld Process Specifications at the end of this section. The pre- ferred method is GMAW (MIG).

(a) Apply root pass welds to the root joint one quadrant at a time, switching to the opposite side of the frame for each quadrant. (Fig. 9)

(b) Clean the welds of any flux and other impu- rities before proceeding with the cover pass welds. (c) Apply the cover pass welds in the same man-

ner as described above. (26) Confirm alignment of the replacement frame

rail tip. (Fig. 15)

NOTE: Any burned surface coatings will need to be removed prior to application of corrosion preventa- tive coatings.

(27) Dress the welded area and apply corrosion

resistant coatings inside and out.

(a) Apply etch-primer to the inside of the frame

rail repair area.

(b) Inside the rail, inject a creeping wax based rust inhibitor compound through the existing holes in the frame ensuring 100% coverage including the space between the original frame rail and the rein- forcing sleeve.

Fig.15FRAMETIPDIMENSIONS

NOTE: All measurements are in mm.

1 - PLP POINT 2 - FRAME 3 - PLP POINT 4 - REPLACEMENT FRAME TIP

FRAMES & BUMPERS

13 - 10
FRAME (Continued)

DR

(c) Apply a durable top coat to the outside of the

repair area. (28) Tighten the front cab mounting bolt to the

FESM bracket to 81 N·m (60 ft. lbs.).

(29) Install the stabilizer bar. (Refer to 2 - SUS- PENSION/FRONT/STABILIZER BAR - INSTALLA- TION)

(30) Install

(Refer to 13 - FRAME & BUMPERS/BUMPERS/FRONT BUMPER - INSTALLATION)

the front bumper.

(31) Install the wire harness and ground strap if

previously removed and install the bolt.

(a) If necessary, re-drill and tap the ground

strap mounting hole (32) Install the front wheelhouse splash shield. (Refer to 23 - BODY/EXTERIOR/FRONT WHEEL- HOUSE SPLASH SHIELD - INSTALLATION)

CAUTION: All welds should conform to DaimlerChrysler vehicle engineering process standard “PS 9472”.

WELD PROCESS SPECIFICATIONS

WELDING PROCESS

FLUX CORED ARC

GAS METAL ARC (MIG)*

SHIELDED METAL ARC

Material Thickness Electrode Type

Electrodes Size Inches Electrode Stick Out Polarity

Shielding Gas

3.7 mm to 4.2 mm

Lincoln Electrical Co. Product #: NR-211 MP (Do Not Substitute)

0.045 Tubular

3/89 - 1/29
Electrode 9-9
Work Piece 9+9
Self Shielded

Gas Flow Rate Wire Feed Speed (inches per minute)

N/A

110 - 130 Vertical Down 70 - 90 Flat & Overhead

3.7 mm to 4.2 mm

AWS ER70S-3

(Do Not Substitute)

0.035 Solid 1/29 - 5/89

Electrode 9+9
Work Piece 9-9

75% Ar 25% CO2

25 - 35 CFM

245 - 250 Vertical Down

210 - 225 Flat &

Overhead

(STICK)

3.7 mm to 4.2 mm

** AWS E 7018

3/329
N/A

Electrode 9+9
Work Piece 9-9
Self Shielded

N/A N/A

Approximate Amperage

Vertical

Flat & Overhead

Voltage Direction of Welding

110 - 130
70 - 90
15 - 18

175
155

19 - 20

85 (3/329 Diameter) 90 (3/329 Diameter)

N/A

Vertical

Vertical Down Hill (only)

Vertical Down Hill (only)

Vertical - Up Hill (only)

Flat & Overhead

Flat - Push or Drag

Flat - Push or Drag

Flat - Drag

*First choice - Gas Metal Arc Welding Process: Butt joints - apply two layers (passes) of weld metal. First pass should only fill approximately 1⁄2 the thick- ness. Vertical position welds - maintain electrode wire at leading edge of weld puddle while traveling down hill to produce maximum penetration into the sleeve. These techniques work for FCAW as well.

**E7018 new electrodes may be exposed to the atmosphere for up to ten hours with no harmful effect. Reconditioning schedules should come from the manufacturer.

DR FRAME (Continued) SERVICE SLEEVE ASSEMBLY

NOTE: Two sleeve halves are included with each kit. Modifications as follow, are necessary to create the correct sleeve assembly for each application.

(1) On 4X2 models, the 9lower9 sleeve is made by cutting off the tab and cutting out a notch in the bot- tom sleeve portion. Round the corners of the cut out to keep stress cracks from forming. On 4X4 models the 9lower9 sleeve is used as provided. (Fig. 16)

FRAMES & BUMPERS

13 - 11

(3) The sleeve halves are shipped slightly over- sized to allow custom fitting to each replacement frame rail tip. It is necessary to grind the mating surfaces to achieve the desired snug fit into the replacement tip (rail tube has increasing height rear- ward of the cut line). Once the two sleeve halves are fitted, bevel the edges 25° - 30°.

NOTE: Scribing a line 2 mm from the cut edge and then grinding back to the mark will simplify the bevel creation process and accuracy.

(4) Remove any burrs at the beveled edges. (5) Using the Weld Process Specifications table, weld the two halves of the repair sleeve together. (Fig. 18)

Fig.164X2LOWERSLEEVECUTLOCATION

1 - SERVICE SLEEVE LOWER HALF 2 - CUT DIMENSION 27 mm (1.06 in.) 3 - CUT DIMENSION 36.1 mm (1.42 in) 4 - 4X2 CUTOUT 5 - FRONT TAB CUT LINE (4X2 ONLY)

(2) On both 4X2 and 4X4 models cut off the front

tab on the upper sleeve portion. (Fig. 17)

Fig.17UPPERSLEEVECUTLOCATION

1 - SERVICE SLEEVE UPPER HALF 2 - CUT LOCATION

Fig.18SERVICESLEEVEASSEMBLY

1 - CENTERLINE SCRIBE MARK 2 - WELD SEAM 3 - REAR TAB (4X4 ONLY) 4 - SCRIBE LINE LOCATION 2 mm (0.08 in.) 5 - FRONT TAB (4X4 ONLY)

(6) Clean the welds of any flux and other impuri- ties and grind smooth before proceeding with the installation of the sleeve.

(7) Find the centerline of the sleeve and scribe a centerline mark. Mark two additional lines 2 mm (0.08 in.) on either side of the centerline mark to help ensure the required 4 mm - 6 mm (0.16 in. - 0.24 in.) weld root gap. (Fig. 18)

FRAMES & BUMPERS

13 - 12
FRAME (Continued) STANDARD PROCEDURE - HYDROFORM FENDER RAIL REPAIR

SAFETY PRECAUTIONS AND WARNINGS

WARNING: USE EYE PROTECTION WHEN GRIND- ING OR WELDING METAL, SERIOUS EYE INJURY CAN RESULT. † BEFORE PROCEEDING WITH FRAME REPAIR INVOLVING GRINDING OR WELDING, VERIFY THAT VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN CONTACT WITH REPAIR AREA, PERSONAL INJURY CAN RESULT. † DO NOT ALLOW OPEN FLAME OR HEAT AND METAL SPATTER FROM ARC WELDING, TO CON- TACT PLASTIC BODY PANELS. FIRE OR EXPLO- SION CAN RESULT. † WHEN WELDED FRAME COMPONENTS ARE REPLACED, ENSURE COMPLETE PENETRATION WELD IS ACHIEVED DURING INSTALLATION. IF NOT, DANGEROUS OPERATING CONDITIONS CAN RESULT. † STAND CLEAR OF CABLES OR CHAINS ON PULLING EQUIPMENT DURING FRAME STRAIGHT- ENING OPERATIONS, PERSONAL INJURY CAN RESULT. † DO NOT VENTURE UNDER A HOISTED VEHI- CLE THAT IS NOT SUPPORTED ON SAFETY STANDS, PERSONAL INJURY CAN RESULT.

CAUTION: Do not reuse damaged fasteners, quality of repair would be suspect. Failure to use only pro- duction fasteners or fasteners of equivalent hard- ness can result in loosening or failure. Do not drill holes in top or bottom frame rail flanges, frame rail failure can result. When using heat to straighten frame components do not exceed 566°C (1050°F), metal fatigue can result.

CAUTION: This repair procedure assumes damage to the right or left hydroform fender rail (Fig. 19). Prior to any repairs, the vehicle must be mounted on the appropriate frame repair equipment (“frame rack”), checked with three dimensional measuring equipment, and necessary pull corrections made. If damage exists in the hydroform fender rail, or cab beyond the area covered by this service procedure after dimensional corrections are made, the hydro- form must be replaced in its entirety. Refer to 23 - BODY/BODY STRUCTURE/WELD LOCATIONS - SPECIFICATIONS, when replacing the entire hydro- form.

DR

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the front wheelhouse splash shield. (Refer to 23 - BODY/EXTERIOR/FRONT WHEEL- HOUSE SPLASH SHIELD - REMOVAL)

(3) Remove the fender. (Refer to 23 - BODY/EXTE-

RIOR/FRONT FENDER - REMOVAL)

(4) Remove the A/C condenser, if required. (Refer to 24 - HEATING & AIR CONDITIONING/PLUMB- ING/A/C CONDENSER - REMOVAL)

(5) Remove the A/C lines, if required. Refer to the Heating and Air Conditioning section of the manual for recommended procedures.

(6) Remove the radiator assembly. (Refer to 7 -

COOLING/ENGINE/RADIATOR - REMOVAL)

(7) Remove the air cleaner and support bracket, if required. (Refer to 9 - ENGINE/AIR INTAKE SYS- TEM/AIR CLEANER ELEMENT - REMOVAL)

(8) Remove the integrated power module. (Refer to 8 - ELECTRICAL/POWER DISTRIBUTION/INTE- GRATED POWER MODULE - REMOVAL)

(9) Remove the bolts and position aside the wire

harness and grounds, if required.

(10) Remove the upper

crossmember. (Refer to 23 - BODY/EXTERIOR/UPPER RADIATOR CROSSMEMBER - REMOVAL)

radiator

(11) Remove the headlamp unit.

(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/ HEADLAMP UNIT - REMOVAL)

(12) Remove the front cab mount to the Front End

Sheet Metal bracket (FESM) bolt.

(13) Remove the bolts attaching the lower radiator crossmember to the hydroform fender rail. (Fig. 19)

CAUTION: Do not use any flame or plasma cutting equipment to cut the frame in this procedure. The inaccurate and high temperatures achieved during flame or plasma cutting will change the metal char- acteristics and may weaken the frame and/or repair location.

(14) Using a reciprocating saw or equivalent, cut the fender rail and shotgun at a straight and square section of the hydroform and remove.

(15) Smooth and square the cut edges. (16) Using the damaged structure as a reference cut the service part at the same location as the first cut. Smooth and square the cut edges.

NOTE: The repair structure should butt up to the remaining structure and provide the same overall vehicle geometry.

DR FRAME (Continued)

FRAMES & BUMPERS

13 - 13

1 - HYDROFORM FENDER RAIL 2 - FRONT END SHEET METAL BRACKET 3 - UPPER RADIATOR CROSSMEMBER BOLTS (4)

4 - UPPER RADIATOR CROSSMEMBER 5 - LOWER RADIATOR CROSSMEMBER BOLTS (8) 6 - LOWER RADIATOR CROSSMEMBER

Fig.19HYDROFORMFENDERRAILS

(17) Fabricate 51 mm (2.0 in.) long repair inserts using scrap from the old structure or the replacement part. It will be necessary to split the inserts on each of their four sides to fit into the hydroform.

(18) Remove any paint or e-coat from the inserts and also to the interior and exterior of the hydro- forms. (19) Cut plug weld holes as described below. † On the upper rail, cut one 13 mm (0.5 in.) hole on each side of the rail, 25 mm (1.0 in.) from the butt joint of the tubes. † On the lower rail, cut one 13 mm (0.5 in.) hole on the top and bottom sides of the rail 25 mm (1.0
in.) from the butt joint of the tube. † On the lower rail, cut two 13 mm (0.5 in.) holes on the inner and outer sides of the rail 25 mm (1.0
in.) from the butt joint of the tube.

CAUTION: Shield the surrounding area and compo- nents from exposure to the welding spatter and heat.

(20) Install the insert 1” into the replacement part

and tack into place with a weld.

(21) Insert the service part into place and using the appropriate measuring equipment, verify the

front end sheet metal bracket’s location in all three (X,Y, and Z) planes of space. (Fig. 20) (22) Complete all 360° plug welds.

NOTE: Before the final welding, use three dimen- sional measuring equipment to ensure the part is in the correct location. Verify that tap plate extrusion at the bottom of the vertical post lines up with the isolator and hole in the frame perch mount. Also ensure the lower radiator closure tube is bolted into the forward shotgun ends.

(23) Complete welding by making a 360° butt weld

around the fender rails.

(24) Metal finish the exposed welds on the hydro-

forms.

(25) Dress the welded area and apply corrosion

resistant coatings inside and out.

(a) Inside the rail, inject a creeping wax based rust inhibitor compound to the inside of the hydro- forms ensuring 100% coverage including the mat- ing face between the fender rail sections and insert such that corrosion protection is restored in the internal cavity.

(b) Apply a durable top coat to the outside of the

repair area.

FRAMES & BUMPERS

13 - 14
FRAME (Continued)

DR

Fig.20ENGINECOMPARTMENT/FRONTSTRUCTURE

(26) Install the front cab mount bolt if previously

removed and tighten to 81 N·m (60 ft. lbs.).

(27) Install the lower radiator crossmember bolts

and tighten to 28 N·m (21 ft. lbs.).

(28) Install the headlamp unit. (Refer to 8 - ELEC- TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD- LAMP UNIT - INSTALLATION)

(29) Install the upper radiator crossmember. (Refer - BODY/EXTERIOR/UPPER RADIATOR

to CROSSMEMBER - INSTALLATION)

23

(30) Install the wire harness and ground if previ-

ously removed and install the bolts.

(31) Install the integrated power module, if previ- ously removed. (Refer to 8 - ELECTRICAL/POWER DISTRIBUTION/INTEGRATED POWER MODULE - INSTALLATION)

(32) Install the air cleaner bracket and air cleaner, if previously removed. (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER ELEMENT - INSTALLATION)

(33) Install the radiator assembly. (Refer to 7 -

COOLING/ENGINE/RADIATOR - INSTALLATION)

(34) Install the A/C lines, if previously removed. Refer to the Heating and Air Conditioning section of the manual for the recommended procedures.

(35) Install

the A/C condenser,

if previously removed. (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING/A/C CONDENSER - INSTAL- LATION)

(36) Install the fender. (Refer to 23 - BODY/EXTE-

RIOR/FRONT FENDER - INSTALLATION)

(37) Install the front wheelhouse splash shield. (Refer to 23 - BODY/EXTERIOR/FRONT WHEEL- HOUSE SPLASH SHIELD - INSTALLATION)

(38) Reconnect the battery ground.

DR FRAME (Continued) STANDARD PROCEDURE - REAR FRAME H-SECTION REPLACEMENT

SAFETY PRECAUTIONS AND WARNINGS

WARNING: USE EYE PROTECTION WHEN GRIND- ING OR WELDING METAL, SERIOUS EYE INJURY CAN RESULT. † BEFORE PROCEEDING WITH FRAME REPAIR INVOLVING GRINDING OR WELDING, VERIFY THAT VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN CONTACT WITH REPAIR AREA, PERSONAL INJURY CAN RESULT. † DO NOT ALLOW OPEN FLAME OR HEAT AND METAL SPATTER FROM ARC WELDING, TO CON- TACT PLASTIC BODY PANELS. FIRE OR EXPLO- SION CAN RESULT. † WHEN WELDED FRAME COMPONENTS ARE REPLACED, ENSURE COMPLETE PENETRATION WELD IS ACHIEVED DURING INSTALLATION. IF NOT, DANGEROUS OPERATING CONDITIONS CAN RESULT. † STAND CLEAR OF CABLES OR CHAINS ON PULLING EQUIPMENT DURING FRAME STRAIGHT- ENING OPERATIONS, PERSONAL INJURY CAN RESULT. † DO NOT VENTURE UNDER A HOISTED VEHI- CLE THAT IS NOT SUPPORTED ON SAFETY STANDS, PERSONAL INJURY CAN RESULT.

CAUTION: Do not reuse damaged fasteners, quality of repair would be suspect. Failure to use only pro- duction fasteners or fasteners of equivalent hard- ness can result in loosening or failure. Do not drill holes in top or bottom frame rail flanges, frame rail failure can result. When using heat to straighten frame components do not exceed 566°C (1050°F), metal fatigue can result.

CAUTION: This procedure is designed to replace the H-section/spare tire support located at the rear of the frame assembly. Prior to any cutting, the vehicle must be mounted on the appropriate frame repair equipment (“frame rack”), checked with three dimensional measuring equipment, and the neces- sary pull corrections made. If damage remains in the frame beyond the area covered by this service part after the pull, the frame must be replaced in its entirety.

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the cargo box. (Refer to 23 - BODY/EX-

TERIOR/CARGO BOX - REMOVAL)

FRAMES & BUMPERS

13 - 15

(3) Remove the trailer hitch. (Refer to 13 - FRAME

BUMPERS/FRAME/TRAILER

HITCH

(4) Raise and support the frame so the tires are off

REMOVAL)

floor.

(5) Remove the shock absorbers. (Refer to 2 - SUS-

PENSION/REAR/SHOCK - REMOVAL)

(6) Remove the rear leaf spring shackle bolts and

let the axle rest on the ground. (Fig. 21)

Fig.21REARSPRING

1 - SPRING SHACKLE 2 - LEAF SPRING EYE BOLT/NUT 3 - REAR LEAF SPRING

(7) Remove the spare wheel. (8) Remove the clip and remove the spare tire

winch tube. (Fig. 22)

Fig.22SPARETIREWINCHTUBE

1 - SPARE TIRE WINCH ASSEMBLY 2 - HAIR PIN CLIP 3 - WINCH TUBE 4 - H-SECTION/SPARE WHEEL SUPPORT

FRAMES & BUMPERS

13 - 16
FRAME (Continued)

DR

(9) Remove the bolts and remove the spare tire

winch. (Fig. 23)

(Refer to 13 - FRAME & BUMPERS/FRAME - SPEC- IFICATIONS - FRAME DIMENSIONS)

CAUTION: Shield the surrounding area and compo- nents from exposure to the welding spatter and heat.

(16) Weld the replacement H-section into position. The welding should be performed in a skip (stitch) type method to minimize the heat buildup following I-CAR or the American Welding Society welding pro- cedures and utilizing the process specifications at the end of this section. Refer to the Weld Process Speci- fications welding schedule below.

(17) Dress the welded area and apply corrosion

resistant coatings inside and out.

(a) Inside the rail, inject a creeping wax based rust inhibitor compound through the existing holes in the frame ensuring 100% coverage including the mating face between the frame and replacement H-section.

(b) Apply a durable top coat to the outside of the

repair area. (18) Position the wiring harness back. (19) Install the spare tire winch and install the

bolts. (Fig. 23)

(20) Tighten the bolts to 41 N·m (30 ft. lbs.). (21) Install the spare tire winch tube and install

the clip. (Fig. 22)

(22) Install the spare tire. (23) Lift the axle into position and install the rear

shackle bolts. (Fig. 21)

(24) Tighten the bolts to 163 N·m (120 ft. lbs.). (25) Install the lower shock absorber bolts. (Refer to 2 - SUSPENSION/REAR/SHOCK - INSTALLA- TION)

(26) Install the trailer hitch. (Refer to 13 - FRAME & BUMPERS/FRAME/TRAILER HITCH - INSTAL- LATION)

(27) Install the cargo box. (Refer to 23 - BODY/EX-

TERIOR/CARGO BOX - INSTALLATION)

(28) Reconnect the battery ground.

Fig.23SPARETIREWINCHASSEMBLY

1 - SPARE TIRE WINCH ASSEMBLY 2 - BOLTS 3 - RETAINER BRACKET 4 - H-SECTION/SPARE WHEEL SUPPORT

(10) Position the wire harness forward of the work

area.

CAUTION: Do not use any flame or plasma cutting equipment to cut the frame in this procedure. The inaccurate and high temperatures achieved during flame or plasma cutting will change the metal char- acteristics and may weaken the frame and/or repair location.

(11) Carefully remove the H-section welds using a

grinder or equivalent tool.

ing welds from the frame.

(12) Remove the H-section and clean any remain-

(13) Trial fit the replacement part. (14) Remove all e-coat from within 25 mm (1.0 in.)

of the weld area.

(15) Using the appropriate measuring equipment, position the replacement part and verify correct posi- tioning in all three (X,Y, and Z) planes of space.

DR FRAME (Continued)

FRAMES & BUMPERS

13 - 17

CAUTION: All welds should conform to DaimlerChrysler vehicle engineering process standard “ps 9472”.

WELD PROCESS SPECIFICATIONS

WELDING PROCESS

FLUX CORED ARC

GAS METAL ARC (MIG)*

SHIELDED METAL ARC

Material Thickness Electrode Type

Electrodes Size Inches Electrode Stick Out Polarity

Shielding Gas

3.7 mm to 4.2 mm

Lincoln Electrical Co. Product #: NR-211 MP (Do Not Substitute)

.045 Tubular 3/89 - 1/29
Electrode 9-9
Work Piece 9+9
Self Shielded

Gas Flow Rate Wire Feed Speed (inches per minute)

N/A

110 - 130 Vertical Down 70 - 90 Flat & Overhead

3.7 mm to 4.2 mm

AWS ER70S-3

(Do Not Substitute)

.035 Solid 1/29 - 5/89

Electrode 9+9
Work Piece 9-9

75% Ar 25% CO2

25 - 35 CFM

245 - 250 Vertical Down

210 - 225 Flat &

Overhead

(STICK)

3.7 mm to 4.2 mm

** AWS E 7018

3/329
N/A

Electrode 9+9
Work Piece 9-9
Self Shielded

N/A N/A

Approximate Amperage

Vertical

Flat & Overhead

Voltage Direction of Welding

110 - 130
70 - 90
15 - 18

175
155

19 - 20

85 (3/329 Diameter) 90 (3/329 Diameter)

N/A

Vertical

Vertical Down Hill (only)

Vertical Down Hill (only)

Vertical - Up Hill (only)

Flat & Overhead

Flat - Push or Drag

Flat - Push or Drag

Flat - Drag

*First choice - Gas Metal Arc Welding Process: Butt joints - apply two layers (passes) of weld metal. First pass should only fill approximately 1⁄2 the thick- ness. Vertical position welds - maintain electrode wire at leading edge of weld puddle while traveling down hill to produce maximum penetration into the sleeve. These techniques work for FCAW as well.

**E7018 new electrodes may be exposed to the atmosphere for up to ten hours with no harmful effect. Reconditioning schedules should come from the manufacturer.

SPECIFICATIONS

SPECIFICATIONS - FRAME DIMENSIONS

NOTE: Frame dimensions are listed in metric scale. All dimensions are from center to center of Princi- pal Locating Point (PLP), or from center to center of PLP and fastener location.

VEHICLE PREPARATION

Position the vehicle on a level work surface. Using screw or bottle jacks, adjust the vehicle PLP heights to the specified dimension above a level work surface. Vertical dimensions can be taken from the work sur- face to the locations indicated were applicable.

INDEX

DESCRIPTION

FIGURE

Frame Dimensional Graphics, Side And Top View 140.5 In Wheelbase - Heavy Duty - 2 Wheel Drive 140.5 In Wheelbase - Heavy Duty - 4 Wheel Drive 160.5 In Wheelbase - Heavy Duty - 2 Wheel Drive 160.5 In Wheelbase - Heavy Duty - 4 Wheel Drive

24

25

26

27

28

FRAMES & BUMPERS

13 - 18
FRAME (Continued)

DR

DR FRAME (Continued)

FRAMES & BUMPERS

13 - 19

FRAMES & BUMPERS

13 - 20
FRAME (Continued)

DR

DR FRAME (Continued)

FRAMES & BUMPERS

13 - 21

FRAMES & BUMPERS

13 - 22
FRAME (Continued)

DR

DR FRAME (Continued) SPECIFICATIONS - TORQUE

TORQUE SPECIFICATIONS

DESCRIPTION Cab mount bolts Cargo box bolts

Front crossmember bolts - 2WD Front crossmember bolts - 4WD

Front skid plate bolts

Lower bumper support bracket bolt Radiator crossmember bolts - lower Radiator crossmember bolts - upper

Rear crossmember - 2WD Rear crossmember - 4WD Rear spring shackle bolts

Spare tire winch bolts

Trailer hitch reinforcement bracket bolt

Transfercase skid plate bolts

Transercase skid plate crossmember bolts Transmission mount to crossmember nuts

FRONT CROSSMEMBER REMOVAL

N·m 81
108
61
102
34
54
28
28
102
102
163
41
170
34
34
61

FRAMES & BUMPERS

13 - 23

Ft. Lbs.

In. Lbs.

60
80
45
75
25
40
21
21
75
75
120
30
125
25
25
45

— — — — — — — — — — — — — — — —

(1) Raise and support

to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)

the vehicle.

(Refer

(2) Remove the front skid plate, if equipped. (Refer to 13 - FRAME & BUMPERS/FRAME/FRONT SKID PLATE - REMOVAL)

(3) Remove the bolts and remove the crossmember.

(Fig. 29) or (Fig. 30)

INSTALLATION

(1) Install the crossmember. (2) Install the bolts; † On 2WD vehicles, tighten the bolts to 61 N·m † On 4WD vehicles, tighten the bolts to 102 N·m

(45 ft. lbs.).

(75 ft. lbs.).

Fig.29FRONTCROSSMEMBER-2WD

1 - CROSSMEMBER 2 - BOLTS (2 PER SIDE)

FRAMES & BUMPERS

13 - 24
FRONT CROSSMEMBER (Continued)

DR

INSTALLATION

(1) Snap the rear tabs over the front crossmember

and install the skid plate.

(2) Install the bolts and tighten to 34 N·m (25 ft.

lbs.).

TRANSMISSION CROSSMEMBER REMOVAL

(1) Raise and support

to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)

the vehicle.

(Refer

(2) Remove

equipped. FRAME/TRANSFER REMOVAL)

the

transfercase

if (Refer to 13 - FRAME & BUMPERS/

PLATE

CASE

plate,

SKID

skid

(3) Support the transmission with a suitable lifting

device.

or (Fig. 33)

(4) Remove the transmission mount nuts. (Fig. 32)

(5) Remove the bolts and remove the crossmember.

Fig.30FRONTCROSSMEMBER-4WD

1 - BOLTS (2 PER SIDE) 2 - CROSSMEMBER

(3) Install the front skid plate, if equipped. (Refer to 13 - FRAME & BUMPERS/FRAME/FRONT SKID PLATE - INSTALLATION)

FRONT SKID PLATE REMOVAL

(1) Raise and support

to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)

the vehicle.

(Refer

(2) Remove the bolts. (Fig. 31) (3) Slide skid plate back off of the crossmember

and remove.

Fig.32REARCROSSMEMBER-2WD

1 - TRANSMISSION MOUNT 2 - REAR CROSSMEMBER 3 - TRANSMISSION MOUNT NUTS (2) 4 - CROSSMEMBER BOLTS (2 PER SIDE)

Fig.31FRONTSKIDPLATE

1 - FRONT CROSSMEMBER 2 - FRONT SKID PLATE 3 - BOLTS (2)

DR TRANSMISSION CROSSMEMBER (Continued)

FRAMES & BUMPERS

13 - 25

(4) Remove the rear two cargo box bolts and loosen the remaining bolts. (Refer to 23 - BODY/EXTERI- OR/CARGO BOX - REMOVAL)

(5) Using a suitable lifting device, lift and support

the rear of the cargo box and remove the hitch.

Fig.33REARCROSSMEMBER-4WD

1 - TRANSMISSION MOUNT 2 - TORSION BAR 3 - CROSSMEMBER BOLTS (3 PER SIDE) 4 - REAR CROSSMEMBER 5 - TRANSMISSION MOUNT NUTS (2)

INSTALLATION

(1) Install the crossmember and install the bolts. (2) Tighten the bolts to 102 N·m (75 ft. lbs.). (3) Install

transmission mount nuts and

the

tighten to 61 N·m (45 ft. lbs.).

(4) Remove the transmission support. (5) Install the transfercase skid plate. (Refer to 13
- FRAME & BUMPERS/FRAME/TRANSFER CASE SKID PLATE - INSTALLATION)

TRAILER HITCH REMOVAL

(1) Remove the rear bumper.

to 13 - FRAME & BUMPERS/BUMPERS/REAR BUMPER - REMOVAL)

(Refer

(2) Remove the hitch bolts. (Fig. 34) (3) Disconnect all wire harness support push pins.

Fig.34TRAILERHITCH

1 - HITCH 2 - HITCH BOLTS (4) 3 - BUMPER BRACKET BOLTS (4) 4 - BUMPER SUPPORT BRACKETS

INSTALLATION

(1) Install the hitch onto the frame rails and make sure the locators on the inside of the hitch brackets are engaged with the holes in the top of the frame rails properly.

(2) Lower the cargo box and install the rear bolts. (Refer to 23 - BODY/EXTERIOR/CARGO BOX - INSTALLATION)

(3) Install the hitch bolts and tighten to 170 N·m

(125 ft. lbs.).

(4) Connect all wire harness support push pins. (5) Install the rear bumper. (Refer to 13 - FRAME & BUMPERS/BUMPERS/REAR BUMPER - INSTAL- LATION)

13 - 26

FRAMES & BUMPERS

DR

TRANSFER CASE SKID PLATE REMOVAL

FRONT TOW HOOK ASSEMBLY REMOVAL

(1) Raise and support

to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCEDURE)

the vehicle.

(Refer

(2) Support the skid plate and remove the bolts.

(Fig. 35)

(3) Remove the skid plate. (4) Support

skid plate

the

remove the bolts.

(5) Remove the skid plate crossmember.

crossmember and

Fig.35TRANSFERCASESKIDPLATE

1 - CROSSMEMBER BOLTS (4) 2 - SKID PLATE CROSSMEMBER 3 - SKID PLATE 4 - SKID PLATE BOLTS (4)

INSTALLATION

(1) Install the skid plate crossmember and install

the bolts.

(2) Tighten the bolts to 34 N·m (25 ft. lbs.). (3) Install the skid plate and install the bolts. (4) Tighten the bolts to 34 N·m (25 ft. lbs.).

(1) Remove front bumper. (Refer to 13 - FRAME &

BUMPER

BUMPERS/BUMPERS/FRONT REMOVAL)

(2) Remove the bolts and remove the tow hook

assembly. (Fig. 36)

Fig.36FRONTTOWHOOKASSEMBLY

1 - BUMPER CENTER SUPPORT BRACKET 2 - BOLTS (6) 3 - TOW HOOK ASSEMBLY

INSTALLATION

(1) Install the tow hook assembly and bolts hand

(2) Install the front bumper. (Refer to 13 - FRAME

& BUMPERS/BUMPERS/FRONT INSTALLATION)

BUMPER

(3) Tighten the tow hook bolts to 68 N·m (50 ft.

tight.

lbs.).

DR

FUEL SYSTEM 14 - 1

FUEL SYSTEM

TABLE OF CONTENTS

FUEL DELIVERY - GAS . . . . . . . . . . . . . . . . . . . . 1
FUEL INJECTION - GAS . . . . . . . . . . . . . . . . . . . 24

FUEL DELIVERY - DIESEL FUEL INJECTION - DIESEL

. . . . . . . . . . . . . . . . . 56
. . . . . . . . . . . . . . . . 79

page

page

FUEL DELIVERY - GAS

TABLE OF CONTENTS

page

page

FUEL DELIVERY - GAS

FUEL PUMP

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE - FUEL SYSTEM

PRESSURE RELEASE . . . . . . . . . . . . . . . . . . . 2

SPECIFICATIONS

FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . 3
TORQUE - FUEL SYSTEM . . . . . . . . . . . . . . . 3

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

FUEL PUMP MODULE

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13

SPECIAL TOOLS

FUEL RAIL

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 5

FUEL FILTER/PRESSURE REGULATOR

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18

FUEL LEVEL SENDING UNIT / SENSOR

FUEL TANK

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . 20
REMOVAL- EXCEPT DIESEL INSTALLATION - EXCEPT DIESEL . . . . . . . . . . 22

FUEL LINES

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8

QUICK CONNECT FITTING

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - QUICK-CONNECT

FITTINGS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

FUEL DELIVERY - GAS DESCRIPTION

The fuel delivery system consists of: † a fuel pump module containing the electric fuel pump, fuel filter/fuel pressure regulator, fuel gauge sending unit (fuel level sensor) and a secondary fuel filter located at the bottom of the pump module † fuel tubes/lines/hoses † a combination fuel filter/fuel pressure regulator

INLET FILTER

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23

† quick-connect fittings † fuel injector rail † fuel tank † fuel tank filler/vent tube assembly † fuel tank filler tube cap † accelerator pedal † throttle cable Certain fuel delivery components can be found in

(Fig. 1).

FUEL DELIVERY - GAS

14 - 2
FUEL DELIVERY - GAS (Continued)

DR

Fig.1FUELDELIVERYCOMPONENTS

1 - FUEL TANK 2 - CHECK VALVE 3 - LIQUID EXPANSION CHAMBER 4 - FUEL FILTER / FUEL PRESSURE REGULATOR 5 - QUICK-CONNECT FITTING AND FUEL LINE (TO ENGINE) 6 - EVAP LINE CONNECTION 7 - LEAK DETECTION PUMP FRESH AIR LINE

8 - LDP FRESH AIR FILTER 9 - LEAK DETECTION PUMP 10 - EVAP CANISTERS (2) 11 - FUEL TANK STRAPS (2) 12 - CHECK VALVE 13 - FUEL PUMP MODULE LOCK RING 14 - FUEL PUMP MODULE

OPERATION

Fuel is returned through the fuel pump module and back into the fuel tank through the fuel filter/ fuel pressure regulator. A separate fuel return line from the engine to the tank is not used.

The fuel tank assembly consists of: the fuel tank, fuel pump module assembly, fuel pump module lock- nut/gasket, and fuel tank check valve (refer to Fuel Tank Check Valve for information).

A fuel filler/vent tube assembly using a pressure/ vacuum, 1/4 turn fuel filler cap is used. The fuel filler tube contains a flap door located below the fuel fill cap.

Also to be considered part of the fuel system is the evaporation control system. This is designed to reduce the emission of fuel vapors into the atmo-

sphere. The description and function of the Evapora- tive Control System is found in Emission Control Systems.

Both fuel filters (at bottom of fuel pump module and within fuel pressure regulator) are designed for extended service. They do not require normal sched- uled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so.

STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE

Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port.

(1) Remove fuel fill cap.

DR FUEL DELIVERY - GAS (Continued)

(2) Remove fuel pump relay from Power Distribu- tion Center (PDC). For location of relay, refer to label on underside of PDC cover.

(3) Start and run engine until it stalls. (4) Attempt restarting engine until

it will no

longer run.

(5) Turn ignition key to OFF position.

CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cyl- inder chamber.

(6) Unplug connector from any fuel injector. (7) Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. (8) Connect other end of jumper wire to positive

side of battery.

SPECIFICATIONS

FUEL SYSTEM PRESSURE

339 kPa +/- 34 kPa (49.2 psi +/- 2 psi).

TORQUE - FUEL SYSTEM

DESCRIPTION

Accelerator Pedal Bracket

Mounting

Accelerator Pedal Position Sensor Bracket-to-Battery

Tray Bolts

Crankshaft Position

Sensor - 3.7L

Crankshaft Position

Sensor - 4.7L

Crankshaft Position

Sensor - 5.7L

Crankshaft Position

Sensor - 5.9L

Crankshaft Position

Sensor - 8.0L

Camshaft Position Sensor

- 3.7L

Camshaft Position Sensor

- 4.7L

Camshaft Position Sensor

- 5.7L

Camshaft Position Sensor

- 8.0L

N-m 12

28

28

12

12

12

12

FUEL DELIVERY - GAS

14 - 3

(9) Connect one end of a second jumper wire to

remaining injector terminal.

CAUTION: Powering an injector for more than a few seconds will permanently damage the injector.

(10) Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds.

(11) Place a rag or towel below fuel line quick-con-

nect fitting at fuel rail.

(12) Disconnect quick-connect fitting at fuel rail.

Refer to Quick-Connect Fittings.

(13) Return fuel pump relay to PDC. (14) One or more Diagnostic Trouble Codes (DTC’s) may have been stored in PCM memory due to fuel pump relay removal. The DRBt scan tool must be used to erase a DTC.

Ft. Lbs.

21

21

In. Lbs.

105

30

105 (+/-20)

70

70

106

106

105 (+/-) 20

50

FUEL DELIVERY - GAS

14 - 4
FUEL DELIVERY - GAS (Continued)

DR

DESCRIPTION Engine Coolant

Temperature Sensor -

3.7L

Engine Coolant

Temperature Sensor -

4.7L

Engine Coolant

Temperature Sensor -

5.7L

Engine Coolant

Temperature Sensor -

5.9L

Engine Coolant

Temperature Sensor -

8.0L

EVAP Canister- to-Bracket

Nuts

EVAP Canister-to-frame

bolts

Fuel Filler Hose Clamp at

Tank

Fuel Filler Housing-to-

Body Screws

Fuel Pump Module Lock

Ring

Fuel Rail Mounting Bolts -

3.7L

Fuel Rail Mounting Bolts -

4.7L

Fuel Rail Mounting Bolts -

5.7L

Fuel Rail Mounting Bolts -

5.9L

Fuel Rail Mounting Bolts -

8.0L

Fuel Tank Mounting Straps

IAC Motor Mounting

Screws - 3.7L

IAC Motor Mounting

Screws - 4.7L

IAC Motor Mounting

Screws - 5.9L

IAC Motor Mounting

Screws - 8.0L

Leak Detection Pump

Mounting Bolt

Map Sensor Mounting

Screws - 3.7L

N-m 11

11

11

11

11

8.5

34

54

11

11

11

23

15

41

8.5

Ft. Lbs.

In. Lbs.

25

40

30

96

96

96

96

96

75

30

17

100

100

100