1999 DODGE RAM Service Repair Manual

components, reverse removal procedure.
Removal (Dakota 4WD & Durango 4WD)
1) Disconnect negative battery cable. Remove oil dipstick.
Drain engine oil. Remove exhaust pipe crossover and lower transmission
cover.
2) Remove front drive axle for access to oil pan. For front
drive axle removal, loosen wheel lug nuts. Remove cotter pin, lock nut
and spring washer. Loosen axle shaft nut with vehicle on floor and
brakes applied. Raise and support vehicle.
CAUTION: DO NOT pull on rubber boot during axle shaft removal. Pull on
outer CV joint only.
3) Remove wheels and skid plate. Remove axle shaft nut.
Remove axle shaft-to-differential flange bolts at front drive axle.
Support axle shaft, and separate axle splines from wheel hub by
pulling inward at outer CV joint.
4) Remove remaining axle shaft. Mark front drive shaft and
transfer case yoke for installation reference. Remove front drive
shaft from transfer case. Disconnect vacuum hoses from shift motor and
electrical connections at shift indicator switch.
5) Support front drive axle using a floor jack. Remove front
drive axle and shift motor bolts. Lower floor jack, and remove front
drive axle with drive shaft. Remove transmission lower cover. Remove
bolts, oil pan and gasket.
Installation
1) To install, reverse removal procedure. Before installing
oil pan, apply RTV sealant where front cover contacts cylinder block,
oil pan side gaskets meet end seals and end seals contact cylinder
block. See Fig. 14.
2) To facilitate oil pan installation, fabricate 4 alignment
dowels from 1 1/2" x 5/16" bolts. See Fig. 15. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table.
3) To install remaining components, reverse removal
procedure. When installing front drive axle, loosely install all bolts
before tightening to specification. Tighten axle shaft nut to
specification with vehicle on ground. See TORQUE SPECIFICATIONS table.
Ensure reference marks on transfer case yoke and front drive shaft are
aligned.
Removal (Ram Pickup & Ram Van/Wagon - 3.9L)
1) Disconnect negative battery cable. Remove oil dipstick. On
Ram Van/Wagon, remove engine cover. On all models, remove air cleaner
and engine controller. Raise and support vehicle. Drain engine oil.
2) Remove left engine-to-transmission strut. Loosen exhaust
pipe support bracket. Disconnect exhaust pipe. On Ram Pickup, remove
oil pan and gasket.
3) On Ram Van/Wagon, remove starter, transmission dust
shield, oxygen sensor and air injection tube. On all models, remove
right engine mount nut. Loosen, but DO NOT remove, left engine mount
nut.
4) Support right side of engine using jackstand. Remove
transmission mount through-bolt, and support transmission using
jackstand. Raise engine and transmission enough for oil pan removal.
Remove bolts, oil pan and gasket.
Installation
1) To install, reverse removal procedure. Before installing
oil pan, apply RTV sealant where front cover contacts cylinder block,
oil pan side gaskets meet end seals and end seals contact cylinder
block. See Fig. 14.

2) To facilitate oil pan installation, fabricate 4 alignment
dowels from 1 1/2" x 5/16" bolts. See Fig. 15. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table. To install remaining
components, reverse removal procedure. Tighten bolts to specification.
See TORQUE SPECIFICATIONS table. To install remaining components,
reverse removal procedure.
Removal (Ram Pickup & Ram Van/Wagon - 5.2L & 5.9L)
Disconnect negative battery cable. Remove oil dipstick. Raise
and support vehicle. Drain engine oil. Remove exhaust pipe. Remove
left engine-to-transmission strut. Remove bolts, oil pan and gasket.
Installation
1) To install, reverse removal procedure. Before installing
oil pan, apply RTV sealant where front cover contacts cylinder block,
oil pan side gaskets meet end seals and end seals contact cylinder
block. See Fig. 14.
2) To facilitate oil pan installation, fabricate 4 alignment
dowels from 1 1/2" x 5/16" bolts. See Fig. 15. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table. To install remaining
components, reverse removal procedure.
Removal (Grand Cherokee)
Disconnect negative battery cable. Remove oil dipstick. Raise
and support vehicle. Drain engine oil. Disconnect O2 sensor. Remove
exhaust pipe and starter. Remove left engine-to-transmission strut.
Disconnect oil level sensor (if equipped). Remove bolts, oil pan and
gasket. DO NOT damage oil level sensor.
Installation
1) To install, reverse removal procedure. Before installing
oil pan, apply RTV sealant where front cover contacts cylinder block,
oil pan side gaskets meet end seals and end seals contact cylinder
block. See Fig. 14.
2) To facilitate oil pan installation on all models,
fabricate 4 alignment dowels from 1 1/2" x 5/16" bolts. See Fig. 15.
Tighten bolts to specification. See TORQUE SPECIFICATIONS table. To
install remaining components, reverse removal procedure.
Fig. 14: Applying Sealant On Oil Pan Sealing Surfaces
Courtesy of Chrysler Corp.

Fig. 15: Oil Pan Alignment Dowel Fabrication/Installation
Courtesy of Chrysler Corp.
OVERHAUL

CYLINDER HEAD
Cylinder Head
Check cylinder head warpage. Repair or replace cylinder head
if warpage exceeds specification. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS.
Valve Springs
1) Check valve spring free length, out-of-square and
pressure. Replace valve spring if not within specification. See VALVES
& VALVE SPRINGS table under ENGINE SPECIFICATIONS.
2) Measure valve spring installed height from bottom of
spring seat (cylinder head surface) to bottom of spring retainer. If
spacers are installed, measure from top of spacer.
3) If height exceeds 1.687" (42.86 mm), install a .066" (1.\
58
mm) thick spacer in cylinder head counterbore to obtain correct
installed spring height. See VALVES & VALVE SPRINGS table.
Valve Stem Oil Seals
Cup-type oil seals are used on all valves. Ensure oversize
valve stem oil seals are used when oversize valves are installed. When
installing valves, DO NOT overcompress valve springs, or damage to
valve stem oil seal may result.
NOTE: DO NOT ream valve guides from standard to maximum oversize in
one step. Ream valve guides to oversize in gradual steps so
guides are reamed true in relation to valve seat. After
reaming valve guides, valve seat runout must be checked.
Valve Guides
Check valve stem oil clearance. Ensure valve stem diameter is
within specification. Valve guide must be reamed for valve with
oversize valve stem if oil clearance exceeds specification. See
CYLINDER HEAD table under ENGINE SPECIFICATIONS. Valves are available
with stems of .015" (.38 mm) and .030" (.76 mm) oversize.
Valve Seat
Check valve seat width and runout. Grind valve seat if not
within specification. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS.
Valves
Ensure valve margin, head diameter and stem diameter are
within specification. See VALVES & VALVE SPRINGS table under ENGINE
SPECIFICATIONS. Valves are available with stems of .015" (.38 mm) and
.030" (.76 mm) oversize.
Valve Seat Correction Angles
Use a 15-degree stone to lower valve seat, and a 60-degree
stone to raise valve seat.
VALVE TRAIN
Rocker Arms & Pivots
Remove rocker arms and pivots. Inspect for wear. Replace as
necessary.
NOTE: Cylinder block must be marked to indicate oversize valve
lifters. See SPECIAL ENGINE MARKS.
Valve Lifters
Measure valve lifter diameter and bore diameter in cylinder

block. Determine oil clearance. Clearance must be within
specification. See VALVE LIFTERS table under ENGINE SPECIFICATIONS.
Cylinder block can be bored for oversize lifters.
CYLINDER BLOCK ASSEMBLY
Piston & Rod Assembly
Install piston with notch or groove on top of piston toward
front of engine (timing chain end) with larger chamfer of connecting
rod bore toward crankshaft journal fillet.
Fitting Pistons
1) Measure piston diameter at top of piston skirt at 90-
degree angle to piston pin axis. Measure cylinder bore diameter below
top surface of cylinder bore, middle of bore and bottom of cylinder
bore.
NOTE: Piston diameter and cylinder bore should be measured at room
temperature of 70
F (21C).
2) Ensure piston diameter and clearance are within
specification. See PISTONS, PINS & RINGS table under ENGINE
SPECIFICATIONS.
Piston Rings
1) Ensure ring end gap and side clearances are within
specification. See PISTONS, PINS & RINGS table under ENGINE
SPECIFICATIONS.
2) Position piston ring gaps in proper location. See Fig. 16.
Compression ring gaps must be staggered so they do not align with oil
ring rail gap. Ensure identification marks (drill point, letter "O",
an oval depression or the word TOP) on compression rings face upward.
Fig. 16: Positioning Piston Rings
Courtesy of Chrysler Corp.
Rod Bearings
1) Crankshaft is marked to indicate undersize rod bearings.
See SPECIAL ENGINE MARKS. When replacing connecting rod bearings,
ensure connecting rod is installed with larger chamfer of connecting
rod bore toward crankshaft journal fillet.
2) Apply light coat of engine oil to connecting rod bolt
threads before tightening nut to specification. See TORQUE
SPECIFICATIONS table. Ensure oil clearance and side play are within
specification. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table
under ENGINE SPECIFICATIONS.
Crankshaft & Main Bearings
1) Crankshaft is marked to indicate undersize main bearings.
See SPECIAL ENGINE MARKS. Main bearing cap location and direction of
installation should be marked before removal.

2) Ensure journal diameter, taper and out-of-round are within
specification. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table
under ENGINE SPECIFICATIONS. Upper main bearings contain oil holes,
while lower bearings installed in main bearing cap do not.
3) Apply light coat of engine oil to threads before
tightening bolt to specification. See TORQUE SPECIFICATIONS table.
Ensure oil clearance and end play are within specification. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table.
CAUTION: Crankshaft journal grinding should not exceed .012" (.30 mm)
under standard size. DO NOT grind thrust surfaces of No. 3
main bearing. Final paper or cloth polishing after regrind
must be done in same direction as engine rotation.
Thrust Bearing
Thrust bearing is located on No. 3 main bearing. Replace
thrust bearing if crankshaft end play is not within specification. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE
SPECIFICATIONS.
NOTE: Cylinder bore should be measured at room temperature of 70
F
(21C).
Cylinder Block
1) Check cylinder bore, out-of-round and taper. Measure
cylinder bore diameter below top surface of cylinder bore, middle of
bore and bottom of cylinder bore. Bore cylinder block if bore diameter
is not within specification. See CYLINDER BLOCK table under ENGINE
SPECIFICATIONS.
NOTE: Cylinder block is marked to indicate oversize valve lifters.
See SPECIAL ENGINE MARKS.
2) Check valve lifter bore diameter. Check for scoring. If
scoring exists or lifter bore diameter is not within specification,
ream cylinder block bore for next oversize valve lifter. See VALVE
LIFTERS table under ENGINE SPECIFICATIONS.
ENGINE OILING
ENGINE LUBRICATION SYSTEM
System has a rotor-type oil pump and full-flow oil filter.
Oil is forced by pump through a series of oil passages in engine to
provide lubrication to engine components. Oil is supplied to rocker
assembly through hollow push rods. Push rods are fed oil from lifters.
See Fig. 17 .
Crankcase Capacity
On 3.9L, oil capacity with oil filter is 4.0 qts. (3.8L). On
5.2L and 5.9L, oil capacity with oil filter is 5.0 qts. (4.7L).
Oil Pressure
Oil pressure is 6 psi (.4 kg/cm
) at idle and 30-80 psi (2.1-
5.6 kg/cm) at 3000 RPM with engine at normal operating temperature.

Fig. 17: Cross-Sectional View Of Engine Oil Circuit
Courtesy of Chrysler Corp.
OIL LINE PLUG
1) The oil line plug is located in vertical passage in rear
of block between oil-to-filter and oil-from-filter passages. See
Fig. 18 . Missing or improperly installed plug could cause erratic, low
or no oil pressure.
2) To check installation, remove oil sending unit and insert
wire down passage. Oil line plug should be 7.50-7.68 in. (190.0-195.2
mm) from machined surface of block. If plug is too high, use suitable
dowel to position properly. If plug is too low, remove oil pan, oil
pump and rear main bearing cap. Use suitable dowel to position
properly.
3) To remove for passage cleaning or plug replacement, drive
plug from oil sending unit hole out bottom of block. When installing

plug, coat outside diameter with Mopar Stud and Bearing Mount Adhesive
or equivalent. Plug should be 2.12-2.31 in. (54.0-57.7 mm) from bottom\
of block.
Fig. 18: Cross-Sectional View Of Oil Line Plug Location
Courtesy of Chrysler Corp.
OIL PUMP
Removal & Disassembly
1) Remove oil pan. See OIL PAN under REMOVAL & INSTALLATION.