1999 DODGE RAM length

OIL PUMP SPECIFICATIONS








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Application Specification
Inner & Outer Rotor Thickness ................ .825" (20.96 mm) Min.\
Outer Rotor Diameter .......................... 2.47" (62.7 mm) Min.\
Outer Rotor-To-Pump Body Clearance ............. .014" (.36 mm) Max.\
Pump Cover Warpage ........................... .0015" (.038 mm) Max.\
Rotor End Clearance ................................. .004" (.10 mm)\
Rotor Tip Clearance ............................ .008" (.20 mm) Max.\
Spring Free Length ................................. 1.95" (49.5 mm)\
Spring Tension ......... 19.5-20.5 Lbs. @ 1.34" (8.8-9.3 kg @ 34 mm)\









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CAUTION: Ensure oil pump fully engages with distributor drive shaft
before tightening bolt. It may be necessary to slightly
rotate oil pump during installation to align with distributor
drive shaft.
Reassembly & Installation
To reassemble, reverse disassembly procedure. Install NEW
relief valve retainer cap and oil seal ring. Tighten pump cover bolts.
Fill rotor cavity with engine oil before installing. To install,
reverse removal procedure.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Axle Bracket-To-Bellhousing Bolt
Dakota 4WD & Durango 4WD ................................. 65 (88)\
Axle Shaft Nut
Dakota 4WD & Durango 4WD ............................... 180 (244)\
Axle Shaft-To-Differential Flange Bolt
Dakota 4WD & Durango 4WD ................................. 65 (88)\
Axle-To-Insulator Bolt
Dakota 4WD & Durango 4WD ................................ 75 (102)\
Camshaft Sprocket Bolt ..................................... 50 (68)\
Camshaft Thrust Plate Bolt ................................. 18 (24)\
Clutch Housing-To-Cylinder Block Bolt
Dakota
(1) ..................................................... 30 (41)
( 2) ..................................................... 50 (68)
Ram Pickup
( 1)
3/8" Bolt ............................................ 33 (45)\
7/16" Bolt ........................................... 50 (68)\
( 2) ........................................................ N/A
Connecting Rod Bolt ........................................ 45 (61)\
Crankshaft Pulley Bolt ..................................... 18 (24)\
Cylinder Head Bolt ( 3)
Step 1 ................................................... 50 (68)\
Step 2 ................................................. 105 (142)\
Step 3 (Verify Torque) ................................. 105 (142\
)
Differential Pinion Nose Bracket-To-Adapter Bolt
Dakota 4WD & Durango 4WD ................................. 65 (88)\
Differential Pinion Nose Bracket-To-Bellhousing Bolt
Dakota 4WD & Durango 4WD ................................. 65 (88)\
Engine Mount Bracket-To-Frame Rail Bolt
Dakota 2WD & Durango 2WD ................................. 30 (41)\

3.9L & 5.2L .......................... .9841-9843 (24.996-25.001)\
5.9L .................................. .9845-9848 (25.006-25.013)\
Length
3.9L & 5.2L ........................... 2.99-3.01 (75.946-76.454)\
5.9L ....................................... 2.67-2.69 (67.8-68.3)\
Piston Fit
3.9L & 5.2L ......................... .00025-.00075 (.0064-.0191)\
5.9L ..................................... .0002-.0007 (.005-.018)\
Rod Fit .............................. (1) .0007-.0014 (.018-.036)
Rings
3.9L & 5.2L
No. 1 & No. 2
End Gap ................................. .010-.020 (.254-.508)\
Side Clearance ........................ .0029-.0038 (.074-.097)\
No. 3 (Oil)
End Gap .................................. .010-.050 (.25-1.27)\
Side Clearance .................... ( 2) .002-.008 (.06-21) Max.
5.9L
No. 1
End Gap ................................... .012-.022 (.30-.55)\
Side Clearance ........................ .0016-.0033 (.041-.084)\
No. 2
End Gap ................................... .022-.031 (.30-.79)\
Side Clearance ........................ .0016-.0033 (.041-.084)\
No. 3 (Oil)
End Gap .................................. .015-.055 (.38-1.40)\
Side Clearance .......................... ( 2) .0080 (.203) Max.
( 1) - Interference fit.
( 2) - Steel rail oil ring should be free in groove, but clearance
within maximum specification.









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VALVES & VALVE SPRINGS








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Application Specification
Intake Valves
Face Angle .......................................... 43.25-43.75

Head Diameter
3.9L & 5.2L ................................... 1.916" (48.66 mm)\
5.9L .......................................... 1.880" (47.75 mm)\
Minimum Margin ................................... .047" (1.19 mm)\
Stem Diameter
3.9L & 5.2L ........................... .311-.312" (7.90-7.92 mm)\
5.9L .................................. .372-.373" (9.45-9.47 mm)\
Exhaust Valves
Face Angle .......................................... 43.25-43-75

Head Diameter
3.9L & 5.2L ................................... 1.624" (41.25 mm)\
5.9L .......................................... 1.617" (41.07 mm)\
Minimum Margin ................................... .047" (1.19 mm)\
Stem Diameter
3.9L & 5.2L ........................... .311-.313" (7.90-7.95 mm)\
5.9L .................................. .371-.372" (9.42-9.45 mm)\
Valve Springs
Free Length .................................... 1.967" (49.96 mm)\
Installed Height ................... 1.625-1.687" (41.28-42.85 mm)\
Lbs. @ In. (kg @ mm)
Pressure
Valve Closed ............................ 85 @ 1.640 (38 @ 41.66)\

No. 1 ................................. 1.998-1.999 (50.75-50.77)\
No. 2 ................................. 1.982-1.983 (50.34-50.37)\
No. 3 ................................. 1.967-1.968 (49.96-49.99)\
No. 4 ................................. 1.951-1.952 (49.56-49.58)\
No. 5 ................................. 1.561-1.562 (39.65-39.67)\
Oil Clearance
Standard ..................................... .001-.003 (.02-.08)\
Wear Limit ............................................ .005 (.13)\
(1) - Bearings are numbered from front of camshaft.









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CYLINDER BLOCK








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Application In. (mm)\
Cylinder Bore
Standard Diameter
3.9L & 5.2L ........................... 3.910-3.912 (99.31-99.36)\
5.9L ................................ 4.000-4.002 (101.60-101.65)\
Maximum Taper ......................................... .010 (.25)\
Maximum Out-Of-Round .................................. .005 (.13)\
Maximum Oversize .................................... .040 (1.016)\









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VALVE LIFTERS








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Application In. (mm)\
Bore Diameter .......................... .9051-.9059 (22.990-23.010)\
Lifter Diameter .................... ( 1) .9035-.9040 (22.949-22.962)
Oil Clearance .............................. .0011-.0024 (.028-.061)\
Push Rod Length ........................ 6.915-6.935 (175.64-176.15)\
( 1) - Standard diameter valve lifter is listed. Oversize valve lifters
are available in .001" (.02 mm), .008" (.20 mm) and .030" (.7\
6
mm).









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NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
REMOVAL
Remove intake and exhaust manifolds and valve cover. Cylinder
head and camshaft carrier bolts (if equipped), should be removed only
when the engine is cold. On many aluminum cylinder heads, removal
while hot will cause cylinder head warpage. Mark rocker arm or
overhead cam components for location.
Remove rocker arm components or overhead cam components.
Components must be installed in original location. Individual design
rocker arms may utilize shafts, ball-type pedestal mounts or no rocker
arms. For all design types, wire components together and identify
according to the corresponding valve. Remove cylinder head bolts.
Note length and location. Some applications require cylinder head
bolts be removed in proper sequence to prevent cylinder head damage.
See Fig. 1 . Remove cylinder head.
Fig. 1: Typical Cylinder Head Tightening or Loosening Sequence
This Graphic For General Information Only
INSTALLATION
Ensure all surfaces and head bolts are clean. Check that head
bolt holes of cylinder block are clean and dry to prevent block damage
when bolts are tightened. Clean threads with tap to ensure accurate
bolt torque.
Install head gasket on cylinder block. Some manufacturer's
may recommend sealant be applied to head gasket prior to installation.
Note that all holes are aligned. Some gasket applications may be
marked so certain area faces upward. Install cylinder head using care
not to damage head gasket. Ensure cylinder head is fully seated on
cylinder block.
Some applications require head bolts be coated with sealant
prior to installation. This is done if head bolts are exposed to water
passages. Some applications require head bolts be coated with light
coat of engine oil.

Install head bolts. Head bolts should be tightened in proper
steps and sequence to specification. See Fig. 1. Install remaining
components. Tighten all bolts to specification. Adjust valves if
required. See VALVE ADJUSTMENT in this article.
NOTE: Some manufacturers require that head bolts be retightened
after specified amount of operation. This must be done to
prevent head gasket failure.
VALVE ADJUSTMENT
Engine specifications will indicate valve train clearance and
temperature at which adjustment is to be made on most models. In most
cases, adjustment will be made with a cold engine. In some cases, both
a cold and a hot clearance will be given for maintenance convenience.
On some models, adjustment is not required. Rocker arms are
tightened to specification and valve lash is automatically set. On
some models with push rod actuated valve train, adjustment is made at
push rod end of rocker arm while other models do not require
adjustment.
Clearance will be checked between tip of rocker arm and tip
of valve stem in proper sequence using a feeler gauge. Adjustment is
made by rotating adjusting screw until proper clearance is obtained.
Lock nut is then tightened. Engine will be rotated to obtain all valve
adjustments to manufacturer's specifications.
Some models require hydraulic lifter to be bled down and
clearance measured. Different length push rods can be used to obtain
proper clearance. Clearance will be checked between tip of rocker arm
and tip of valve stem in proper sequence using a feeler gauge.
On overhead cam engines designed without rocker arms actuate
valves directly on a cam follower. A hardened, removable disc is
installed between the cam lobe and lifter. Clearance will be checked
between cam heel and adjusting disc in proper sequence using a feeler
gauge. Engine will be rotated to obtain all valve adjustments.
On overhead cam engines designed with rocker arms, adjustment
is made at push rod end of rocker arm. Ensure that the valve to be
adjusted is riding on the heel of the cam on all engines. Clearance
will be checked between tip of rocker arm and tip of valve stem in
proper sequence using a feeler gauge. Adjustment is made by rotating
adjusting screw until proper clearance is obtained. Lock nut is then
tightened. Engine will be rotated to obtain all valve adjustments to
manufacturer's specifications.
CYLINDER HEAD OVERHAUL
* PLEASE READ THIS FIRST *
NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
DISASSEMBLY
Mark valves for location. Using valve spring compressor,
compress valve springs. Remove valve locks. Carefully release spring
compressor. Remove retainer or rotator, valve spring, spring seat and
valve. See Fig. 2.

On cast cylinder heads, if warpage exceeds .003" (.08 mm)
in a 6" span, or .006" (.15 mm) over total length, cylinder head must
be resurfaced. On most aluminum cylinder heads, if warpage exceeds .
002" (.05 mm) in any area, cylinder head must be resurfaced. Warpage
specification may vary with manufacturer.
Cylinder head thickness should be measured to determine
amount of material which can be removed before replacement is
required. Cylinder head thickness must not be less than manufacturer's
specifications.
If cylinder head required resurfacing, it may not align
properly with intake manifold. On "V" type engines, misalignment is
corrected by machining intake manifold surface that contacts cylinder
head. Cylinder head may be machined on surface that contacts intake
manifold.
Using oil stone, remove burrs or scratches from all sealing
surfaces.
VALVE SPRINGS
Inspect valve springs for corroded or pitted valve spring
surfaces which may lead to breakage. Polished spring ends caused by
a rotating spring, indicates that spring surge has occurred. Replace
springs showing evidence of these conditions.
Inspect valve springs for squareness using a 90 degree
straightedge. See Fig. 4. Replace valve spring if out-of-square
exceeds manufacturer's specification.
Fig. 4: Checking Valve Spring Squareness - Typical
This Graphic For General Information Only
Using vernier caliper, measure free length of all valve
springs. Replace springs if not within specification. Using valve

Fig. 6: Measuring Valve Stem-to-Guide Clearance - Typical
This Graphic For General Information Only
Lower valve approximately 1/16" below valve seat. Push valve
stem against valve guide as far as possible. Adjust dial indicator to
zero. Push valve stem in opposite direction and note reading.
Clearance must be within specification.
If valve guide clearance exceeds specification, valves with
oversize stems may be used or valve guide must be replaced. On some
applications, a false guide is installed, then reamed to proper
specification. Valve guide reamer set is used to ream valve guide to
obtain proper clearance for new valve.
Reaming Valve Guide
Select proper reamer for valve stem. Reamer must be of
proper length to provide clean cut through entire length of valve
guide. Install reamer in valve guide and rotate to cut valve guide.
See Fig. 7 .

using ridge reamer. DO NOT remove an excessive amount of material.
Ensure ridge is completely removed.
PISTON & CONNECTING ROD REMOVAL
Note top of piston. Some pistons may contain a notch, arrow
or be marked "FRONT". Piston must be installed in proper direction to
prevent damage with valve operation.
Check that connecting rod and cap are numbered for cylinder
location and which side of cylinder block the number faces. Proper cap
and connecting rod must be installed together. Connecting rod cap must
be installed on connecting rod in proper direction to ensure bearing
lock procedure. Mark connecting rod and cap if necessary. Pistons must
be installed in original location.
Remove cap retaining nuts or bolts. Remove bearing cap.
Install stud protectors on connecting rod bolts. This protects
cylinder walls from scoring during removal. Ensure proper removal of
ridge. Push piston and connecting rod from cylinder. Connecting rod
boss can be tapped with a wooden dowel or hammer handle to aid in
removal.
PISTON & CONNECTING ROD
Disassembly
Using ring expander, remove piston rings. Remove piston pin
retaining rings (if equipped). On pressed type piston pins, special
fixtures and procedures according to manufacturer must be used to
remove piston pins. Follow manufacturer's recommendations to avoid
piston distortion or breakage.
Cleaning
Remove all carbon and varnish from piston. Pistons and
connecting rods may be cleaned in cold type chemical tank. Using ring
groove cleaner, clean all deposits from ring grooves. Ensure all
deposits are cleaned from ring grooves to prevent ring breakage or
sticking. DO NOT attempt to clean pistons using wire brush.
Inspection
Inspect pistons for nicks, scoring, cracks or damage in ring
areas. Connecting rod should be checked for cracks using Magnaflux
procedure. Piston diameter must be measured in manufacturers specified
area.
Using telescopic gauge and micrometer, measure piston pin
bore of piston in 2 areas, 90 degrees apart. This is done to check
diameter and out-of-round.
Install proper bearing cap on connecting rod. Ensure bearing
cap is installed in proper location. Tighten bolts or nuts to
specification. Using inside micrometer, measure inside diameter in 2
areas, 90 degrees apart.
Connecting rod I.D. and out-of-round must be within
specification. Measure piston pin bore I.D. and piston pin O.D. All
components must be within specification. Subtract piston pin diameter
from piston pin bore in piston and connecting rod to determine proper
fit.
Connecting rod length must be measured from center of
crankshaft journal inside diameter to center of piston pin bushing
using proper caliper. Connecting rods must be the same length.
Connecting rods should be checked on an alignment fixture for bent or
twisted condition. Replace all components which are damaged or not
within specification.
PISTON & CYLINDER BORE FIT