1998 DODGE RAM 1500 service

REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Remove the air cleaner(Refer to 9 - ENGINE/
AIR INTAKE SYSTEM - REMOVAL).
(3) Remove intake manifold(Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - REMOVAL).
(4) Remove cylinder head cover(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(5) Remove rocker arm assembly and push rod-
s(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARM / ADJUSTER ASSY - REMOVAL). Identify
push rods to ensure installation in original location.
(6) Remove the cylinder head(Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(7) Remove bolt from tappet guide holder.
(8) Remove tappet guide holder.
(9) Pull tappet out of bore with a twisting motion.
If all tappets are to be removed and reused, identify
tappets to ensure installation in original location.
(10) Check camshaft lobes for abnormal wear.
INSTALLATION
(1) Lubricate tappets.
(2) Install tappets in their original positions.
(3)
Install tappet guide holder. Install the tappet
guide holder bolt and tighten to 12 N´m (106 in. lbs.)
torque.
(4) Install cylinder head(Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
(5) Install pushrods and rocker arm assembly(Re-
fer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARM / ADJUSTER ASSY - INSTALLATION).
(6) Install cylinder head cover(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(7)
Install intake manifold(Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSTALLATION).
(8) Install the air cleaner(Refer to 9 - ENGINE/
AIR INTAKE SYSTEM - INSTALLATION).
(9) Connect the negative cable to the battery.
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.
(10) Road test vehicle and check for leaks.
PISTON & CONNECTING ROD
DESCRIPTION
CAUTION: Do not use a metal stamp to mark con-
necting rods as damage may result, instead use ink
or a scratch awl.The pistons are made of a high strength aluminum
alloy. Piston skirts are coated with a solid lubricant
(Molykote) to reduce friction and provide scuff resis-
tance. The piston top ring groove and land is anod-
ized. The connecting rods are made of forged
powdered metal, with a ªfractured capº design. A
pressed fit piston pin is used to attach the piston and
connecting rod.
STANDARD PROCEDUREÐPISTON FITTING
(1) To correctly select the proper size piston, a cyl-
inder bore gauge, capable of reading in 0.003 mm (
.0001 in.) INCREMENTS is required. If a bore gauge
is not available, do not use an inside micrometer.
(2) Measure the inside diameter of the cylinder
bore at a point 38.0 mm (1.5 inches) below top of
bore. Start perpendicular (across or at 90 degrees) to
the axis of the crankshaft at point A and then take
an additional bore reading 90 degrees to that at point
B (Fig. 11).
(3) The coated pistons will be serviced with the
piston pin and connecting rod pre-assembled. The
piston-rod assembly is specific for the left cylinder
bank ( odd numbered) and the right cylinder bank (
even numbered) and must not be interchanged.
(4) The coating material is applied to the piston
after the final piston machining process. Measuring
the outside diameter of a coated piston will not pro-
vide accurate results (Fig. 10). Therefore measuring
the inside diameter of the cylinder bore with a dial
Bore Gauge isMANDATORY. To correctly select the
proper size piston, a cylinder bore gauge capable of
reading in 0.003 mm (.0001 in.) increments is
required.
Fig. 10 MOLY COATED PISTON
1 - MOLY COATED
2 - MOLY COATED
DRENGINE - 5.7L 9 - 211
HYDRAULIC TAPPETS (Continued)

(8) Torque the (3) bolts that attach the front axle
to the left engine bracket to 101 N´m (75 ft. lbs.).
(9) Install the engine oil filter, if removed.
(10) Install the front crossmember(Refer to 13 -
FRAME & BUMPERS/FRAME/FRONT CROSS-
MEMBER - INSTALLATION).
(11) Install the skid plate.
(12) Lower the vehicle.
(13) Reconnect the negative battery cable.
REAR MOUNT
REMOVAL
(1) Raise the vehicle on a hoist.
(2) Using a suitable jack, support transmission.
(3) Remove the nuts from the transmission mount
(Fig. 26).
(4) Remove the two bolts that attach the transmis-
sion mount to the engine bracket.
(5) Raise the transmission enough to remove the
mount from the crossmember.
(6) Remove the mount.
INSTALLATION
NOTE: Threadlocking compound must be applied to
the bolts before installation.(1) Install the two bolts that attach the transmis-
sion mount to the transmission bracket.
(2) Torque the bolts to 61N´m (45 ft.lbs.) torque.
(3) Lower the transmission so the transmission
mount rests on the crossmember, and the studs of
the transmission mount are aligned in the slots in
the crossmember.
(4) Install the nuts onto the transmission mount
studs through the crossmember access slot.
(5) Torque the nuts to 54N´m (40 ft. lbs.).
LUBRICATION
DESCRIPTION
The lubrication system (Fig. 27) is a full flow fil-
tration pressure feed type.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CHECKING
ENGINE OIL PRESSURE
(1) Remove oil pressure sending unit and install
gauge assembly C-3292.
(2) Run engine until thermostat opens.
(3) Oil Pressure:
²Curb Idle±25 kPa (4 psi) minimum
²3000 rpm±170 - 758 kPa (25 - 110 psi)
(4) If oil pressure is 0 at idle, shut off engine.
Check for a clogged oil pick-up screen or a pressure
relief valve stuck open.
DIAGNOSIS AND TESTING - ENGINE OIL LEAK
Begin with a thorough visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair per service manual instructions.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24 km (15 miles), and
repeat inspection.If the oil leak source is not pos-
itively identified at this time, proceed with the air
leak detection test method.
Fig. 26 TRANSMISSION MOUNT
1 - MOUNT
2 - CROSSMEMBER
3 - NUT
4 - BOLT
9 - 220 ENGINE - 5.7LDR
FRONT MOUNT (Continued)

Air Leak Detection Test Method
(1) Remove the PCV valve from the IAFM. Cap or
plug the PCV valve grommet.
(2) Attach an air hose with pressure gauge and
regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kPa (3 PSI) of test pressure.
(3) Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provide the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.(4) If the leakage occurs at the rear oil seal area,
refer to the section, Inspection for Rear Seal Area
Leak.
(5) If no leaks are detected, turn off the air supply
and remove the air hose and all plugs and caps.
Install the PCV valve.
(6) Clean the oil off the suspect oil leak area using
a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
Fig. 27 Engine Oil Lubrication System
DRENGINE - 5.7L 9 - 221
LUBRICATION (Continued)

If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak:
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, distributor seal,
camshaft bore cup plugs oil galley pipe plugs, oil
filter runoff, and main bearing cap to cylinder
block mating surfaces.
(4) If no leaks are detected, pressurize the crank-
case as outlined in the, Inspection (Engine oil Leaks
in general)
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled.
OIL
STANDARD PROCEDURE - ENGINE OIL
SERVICE
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certi-
fied. MOPARtprovides engine oils that conform to
this service grade.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. Use only engine oils with multi-
ple viscosities such as 5W-30 in the 5.7L engines.
These are specified with a dual SAE viscosity grade
which indicates the cold-to-hot temperature viscosity
range. Select an engine oil that is best suited to your
particular temperature range and variation.
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for
gasoline engines. The designation of ENERGY CON-
SERVING is located on the label of an engine oil con-
tainer.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the label
of engine oil plastic bottles and the top of engine oil
cans (Fig. 28).
OIL LEVEL INDICATOR (DIPSTICK)
The engine oil level indicator is located at the left
hand of the engine on the 5.7L engines.
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil,
pressure loss or oil foaming can result.
Inspect engine oil level approximately every 800
kilometers (500 miles). Unless the engine has exhib-
ited loss of oil pressure, run the engine for about ten
Fig. 28 API SYMBOL
9 - 222 ENGINE - 5.7LDR
LUBRICATION (Continued)

CRANKSHAFT OIL SEAL - FRONT
REMOVAL............................275
INSTALLATION........................275
CRANKSHAFT OIL SEAL - REAR
REMOVAL............................276
INSTALLATION........................276
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL............................277
INSTALLATION........................277
SOLID LIFTERS/TAPPETS
REMOVAL............................279
CLEANING...........................279
INSPECTION.........................279
INSTALLATION........................280
PISTON & CONNECTING ROD
DESCRIPTION........................281
STANDARD PROCEDURE - HEAD GASKET
SELECTION.........................281
REMOVAL............................281
CLEANINGÐPISTON AND CONNECTING
ROD ..............................282
INSPECTION
INSPECTION - PISTONS...............282
INSPECTIONÐCONNECTING ROD.......283
INSTALLATION........................283
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING............................284
VIBRATION DAMPER
REMOVAL............................285
INSPECTION.........................285
INSTALLATION........................286
FRONT MOUNT
REMOVAL............................286
INSTALLATION........................287
REAR MOUNT
REMOVAL............................288
INSTALLATION........................288
LUBRICATION
DESCRIPTION........................289
OPERATION..........................289
DIAGNOSIS AND TESTINGÐENGINE OIL
PRESSURE.........................289
OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL
LEVEL.............................292STANDARD PROCEDURE - ENGINE OIL
SERVICE...........................292
OIL COOLER & LINES
CLEANING
CLEANING AND INSPECTION...........293
OIL FILTER
REMOVAL............................293
INSTALLATION........................293
OIL PAN
REMOVAL............................293
CLEANING...........................293
INSPECTION.........................293
INSTALLATION........................293
OIL PRESSURE RELIEF VALVE
REMOVAL............................294
CLEANING...........................294
INSPECTION.........................294
INSTALLATION........................294
OIL PRESSURE SWITCH
REMOVAL............................294
INSTALLATION........................294
OIL PUMP
REMOVAL............................294
CLEANING...........................295
INSPECTION.........................295
INSTALLATION........................296
INTAKE MANIFOLD
REMOVAL............................297
CLEANING...........................297
INSPECTION.........................297
INSTALLATION........................298
EXHAUST MANIFOLD
REMOVAL............................298
CLEANING...........................298
INSPECTION.........................298
INSTALLATION........................298
VALVE TIMING
STANDARD PROCEDURE - TIMING
VERIFICATION.......................299
GEAR HOUSING
REMOVAL............................299
INSTALLATION........................300
GEAR HOUSING COVER
REMOVAL............................301
INSTALLATION........................301
DRENGINE 5.9L DIESEL 9 - 231

ENGINE 5.9L DIESEL
DESCRIPTION
The cylinder block is constructed of cast iron. The
casting is a skirted design which incorporates longi-
tudal ribs for superior strength and noise reduction.
The block incorporates metric straight thread o-ring
fittings at lubrication oil access points. The engine
(Fig. 1) is manufactured with the cylinders being a
non-sleeved type cylinder. However, one approved
service method is to bore out the cylinders and add
cylinder sleeves to the cylinder block.
The cylinders are numbered front to rear (Fig. 2); 1
to 6. The firing order is 1±5±3±6±2±4.
Fig. 1 CumminsT24-Valve Turbo-Diesel Engine
Fig. 2 Cylinder Numbering
9 - 232 ENGINE 5.9L DIESELDR

EXCESSIVE BLUE SMOKE
POSSIBLE CAUSE CORRECTION
Dirty air cleaner or restricted turbocharger intake duct. Check Filter MinderTat air filter housing. (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
ELEMENT - REMOVAL).
Air leak in boost system between turbocharger
compressor outlet and intake manifold.Service air charge system..
Obstruction in exhaust manifold. Remove exhaust manifold and inspect for blockage
(Refer to 9 - ENGINE/MANIFOLDS/EXHAUST
MANIFOLD - REMOVAL).
Restricted turbocharger drain tube. Remove turbocharger drain tube and remove
obstruction.
Crankcase ventilation system plugged. Inspect crankcase ventilation system for function
Valve seals are worn, brittle, or improperly installed. Replace valve stem oil seals (Refer to 9 - ENGINE/
CYLINDER HEAD/INTAKE/EXHAUST VALVES &
SEATS - REMOVAL).
Valve stems and/or guides are worn. Remove valves and inspect valves and guides. (Refer
to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
Broken or Improperly installed piston rings. Tear down engine and inspect piston rings.
Excessive piston ring end gap. Remove pistons and measure piston ring end gap
(Refer to 9 - ENGINE/ENGINE BLOCK/PISTON RINGS
- STANDARD PROCEDURE).
Excessive cylinder bore wear and taper. Remove pistons and measure cylinder bore wear and
taper (Refer to 9 - ENGINE/ENGINE BLOCK -
STANDARD PROCEDURE).
Cylinder damage. Remove pistons and inspect cylinder bore for cracks or
porosity. Repair with cylinder liner if necessary. (Refer
to 9 - ENGINE/ENGINE BLOCK - STANDARD
PROCEDURE).
Piston damage. Remove pistons and inspect for cracks, holes. Measure
piston for out-of-round and taper (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON & CONNECTING
ROD - INSPECTION).
Turbocharger failure. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - INSPECTION).
9 - 238 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

(7) With the engine in this position, valve lash can
be measured at the remaining rocker arms:INTAKE
3±5±6 / EXHAUST 2±4±6. Use the same method as
above for determining whether adjustment is neces-
sary, and adjust those that are found to be outside of
the limits.
(8) Install the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(9) Connect the battery negative cables.
REMOVAL - VALVE SPRINGS AND SEALS
(1) Disconnect the battery negative cables.
(2) Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(3) Disconnect rocker housing injector harness con-
nector. Remove all injector harness solenoid nuts.
(4) Remove injector(s) for cylinder(s) to be serviced.
Refer to Group 14 for injector removal.
(5) Remove the rocker housing.
(6) Remove the rocker arms and crossheads from
the cylinder(s) to be serviced. Mark each component
so they can be installed in their original position.
(7) Using the crankshaft barring tool #7471±B
(Fig. 33), rotate the engine to position the damper
mark in the 12 o'clock position.At this engine posi-
tion, cylinders #1 and #6 can be serviced.
(8) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(9) With the damper TDC mark in the 12 o'clock
position, add a paint mark anywhere on the gear
housing cover next to the crankshaft damper. Place
another mark on the vibration damper in alignment
with the mark you just made on the cover.(10) Divide the crankshaft damper into three
equally sized segments as follows:
(a) Using a tape measure, measure the circum-
ference of the crankshaft damper and divide the
measurement by three (3).
(b) Measure that distance in a counter-clockwise
direction from the first balancer mark and place
another mark on the balancer.
(c) From the second damper mark, again mea-
sure in a counter-clockwise direction and place a
mark on the damper at the same distance you
measured when placing the second damper mark.
The damper should now be marked in three
equally spaced locations and the damper TDC
mark should be in the 12 o'clock position.
(d) Remove injectors, fuel lines, and high pres-
sure connectors for every cylinder that requires
repair.
(11) Compress the valve springs at cyls. #1 and #6
as follows:
(a) Install the valve spring compressor mounting
base as shown in (Fig. 34).
(b) Install the top plate, washer, and nut. Using
a suitable wrench tighten the nut (clock-wise) (Fig.
35) to compress the valve springs and remove the
collets.
(c) Rotate the compressor nut counter-clockwise
to relieve tension on springs. Remove spring com-
pressor.
(d) Remove and replace retainers, springs, and
seals as necessary.
(e)Do not rotate the engine until the
springs and retainers are re-installed.
(f) Install seals, springs and retainers. Install
spring compressor, compress valve springs and
install the collets.
Fig. 32 Measuring Valve Lash - Typical
1 - INTAKE
2 - FEELER GAUGE
3 - EXHAUST
Fig. 33 Rotating Engine with Barring Tool - Typical
1 - REAR FLANGE
2 - BARRING TOOL
9 - 260 ENGINE 5.9L DIESELDR
INTAKE/EXHAUST VALVES & SEATS (Continued)