1999 DODGE RAM Service Repair Manual

Remove bolts and oil pump from rear main bearing cap.
2) Remove cotter pin. Drill a 1/8" (3.17 mm) hole into relie\
f
valve retainer cap and insert a self-tapping sheet metal screw into
cap. Clamp screw into vise. While supporting pump, remove retainer cap
by tapping pump body using soft-face hammer.
3) Discard retainer cap, and remove spring and relief valve.
Remove pump cover and discard oil seal ring. Remove inner rotor and
shaft and outer rotor. See Fig. 19.
Fig. 19: Exploded View Of Oil Pump Assembly
Courtesy of Chrysler Corp.
Inspection
1) Inspect components for damage. Using feeler gauge and
straightedge, check pump cover flatness. Measure thickness of inner
and outer rotors. Measure outer rotor outside diameter. Replace rotors
if not to specification. See OIL PUMP SPECIFICATIONS table.
2) Install outer rotor into pump body. Press outer rotor to
one side, and measure clearance between outer rotor and pump body.
Replace oil pump assembly if clearance exceeds specification. See OIL
PUMP SPECIFICATIONS table.
3) With outer rotor installed in pump body, install inner
rotor and shaft into pump body. Measure rotor tip clearance between
inner and outer rotors. Replace rotors if clearance exceeds
specification. See OIL PUMP SPECIFICATIONS table.
4) With rotors installed in pump body, place a straightedge
(between bolt holes) across face of pump body. Measure rotor end
clearance between rotors and straightedge. Replace oil pump assembly
if clearance exceeds specification. See OIL PUMP SPECIFICATIONS table.
5) Ensure relief valve slides freely in bore. Check free
length and tension of relief valve spring. Replace spring if not
within specification. See OIL PUMP SPECIFICATIONS table.

OIL PUMP SPECIFICATIONS








\









\









\









\









\









\









\







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)\









\









\









\









\









\









\









\







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








\









\









\









\









\









\









\







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)\

Engine Mount Through-Bolt
Dakota 2WD & Durango 2WD ................................. 50 (68)\
Dakota 4WD, Durango 4WD & Ram Pickup .................... 75 (102)\
Grand Cherokee ............................................. 60 (81)\
Engine Mount-To-Cylinder Block Bolt
Dakota & Durango ......................................... 30 (41)\
Ram Pickup ............................................... 60 (81)\
Ram Van/Wagon & Grand Cherokee ............................. 65 (88)\
Engine Mount-To-Frame Bracket Bolt/Nut
Ram Pickup & Ram Van/Wagon .............................. 75 (102)\
Exhaust Manifold Bolt & Nut
Durango .................................................. 18 (24)\
All Others ................................................. 25 (34)\
Flywheel/Flexplate-To-Crankshaft Bolt ...................... 55 (75)\
Front Cover Bolt ........................................... 30 (41)\
Heat Shield Bolts .......................................... 30 (41)\
Main Bearing Cap Bolt ..................................... 85 (115)\
Oil Drain Plug ............................................. 25 (34)\
Oil Filter Adapter Stud .................................... 50 (68)\
Oil Pan Bolt ............................................... 18 (24)\
Oil Pump Bolt .............................................. 30 (41)\
Rocker Arm Bolt ............................................ 21 (28)\
Shift Motor Bolt
Dakota 4WD & Durango 4WD ................................. 65 (88)\
Spark Plug ................................................. 30 (41)\
Starter Bolts .............................................. 50 (68)\
Throttle Body Bolt ......................................... 17 (23)\
Transfer Case Yoke Bolt
Dakota 4WD & Durango 4WD ................................. 20 (27)\
Vibration Damper Bolt .................................... 135 (183)\
Water Pump Bolt ............................................ 30 (41)\
INCH Lbs. (N.m)
Intake Manifold Bolt ( 4)
Step 1 .................................................. 24 (2.7)\
Step 2 .................................................. 48 (5.4)\
Step 3 .................................................. 84 (9.5)\
Step 4 (Verify Torque All Bolts) ........................ 84 (9.5\
)
Intake Manifold Plenum Pan Bolt
Step 1 .................................................. 24 (2.7)\
Step 2 .................................................. 48 (5.4)\
Step 3 .................................................. 84 (9.5)\
Step 4 (Verify Torque) .................................. 84 (9.5\
)
Oil Pump Cover Bolt ........................................ 97 (11)\
Valve Cover Bolts .......................................... 95 (11)\
( 1) - Bolts through clutch housing into cylinder block.
( 2) - Bolts through cylinder block into clutch housing.
( 3) - Tighten bolts in sequence. See 7.
( 4) - Tighten bolts in sequence. See 5 and 6.









\









\









\









\









\









\









\







ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS (3.9L)








\









\









\









\









\









\









\







Application Specification
Displacement .................................... 239 Cu. In. (3.9L)\
Bore ............................................... 3.91" (99.3 mm)\
Stroke ............................................. 3.31" (84.1 mm)\

Compression Ratio ............................................ 9.1:1
Fuel System .................................................... PFI









\









\









\









\









\









\









\







GENERAL SPECIFICATIONS (5.2L)








\









\









\









\









\









\









\







Application Specification
Displacement .................................... 318 Cu. In. (5.2L)\
Bore ............................................... 3.91" (99.3 mm)\
Stroke ............................................. 3.31" (84.1 mm)\
Compression Ratio ............................................ 9.1:1
Fuel System .................................................... PFI









\









\









\









\









\









\









\







GENERAL SPECIFICATIONS (5.9L)








\









\









\









\









\









\









\







Application Specification
Displacement .................................... 360 Cu. In. (5.9L)\
Bore .............................................. 4.00" (101.6 mm)\
Stroke ............................................. 3.58" (90.9 mm)\
Compression Ratio ............................................ 9.1:1
Fuel System .................................................... PFI









\









\









\









\









\









\









\







CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS








\









\









\









\









\









\









\







Application In. (mm)\
Crankshaft End Play
Standard ..................................... .002-.007 (.05-.18)\
Wear Limit ............................................ .010 (.25)\
Main Bearings
Journal Diameter
3.9L & 5.2L ....................... 2.4995-2.5005 (63.487-63.513)\
5.9L .............................. 2.8095-2.8105 (71.361-71.387)\
Journal Out-Of-Round .................................. .001 (.03)\
Journal Taper ......................................... .001 (.03)\
Oil Clearance
Journal No. 1
Standard .............................. .0005-.0015 (.013-.038)\
Wear Limit ....................................... .0015 (.038)\
All Others
Standard .............................. .0005-.0020 (.013-.051)\
Wear Limit ....................................... .0025 (.064)\
Connecting Rod Bearings
Journal Diameter ..................... 2.124-2.125 (53.950-53.975)\
Journal Out-Of-Round .................................. .001 (.03)\
Journal Taper ......................................... .001 (.03)\
Oil Clearance
Standard ................................ .0005-.0022 (.013-.056)\
Wear Limit ......................................... .0025 (.064)\
Side Play .................................... .006-.014 (.15-.36)\









\









\









\









\









\









\









\







PISTONS, PINS & RINGS








\









\









\









\









\









\









\







Application In. (mm)\
Piston Clearance ........................... .0005-.0015 (.013-.038)\
Pins
Diameter

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.









\









\









\









\









\









\









\







VALVES & VALVE SPRINGS








\









\









\









\









\









\









\







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)\

Valve Open ............................. 200 @ 1.212 (89 @ 30.89)\









\









\









\









\









\









\









\







CYLINDER HEAD








\









\









\









\









\









\









\







Application Specification
Maximum Warpage ................ .00075" Per 1" (.0191 mm Per 25 mm)\
Valve Seats
Intake Valve
Seat Angle ......................................... 44.25-44.75

Seat Width .............................. .040-.060" (1.0-1.5 mm)\
Maximum Seat Runout .............................. .003" (.08 mm)\
Exhaust Valve
Seat Angle ......................................... 44.25-44.75

Seat Width .............................. .060-.080" (1.5-2.0 mm)\
Maximum Seat Runout .............................. .003" (.08 mm)\
Valve Guides
Intake Valve
Valve Guide I.D.
3.9L & 5.2L ......................... .313-.314" (7.95-7.96 mm)\
5.9L ................................ .374-.375" (9.50-9.53 mm)\
Valve Stem-To-Guide Oil Clearance
Standard .............................. .001-.003" (.02-.08 mm)\
Wear Limit ................................. (1) .017" (.43 mm)
Exhaust Valve
Valve Guide I.D.
3.9L & 5.2L ......................... .313-.314" (7.95-7.98 mm)\
5.9L ................................ .374-.375" (9.50-9.53 mm)\
Valve Stem-To-Guide Oil Clearance
Standard .............................. .001-.003" (.02-.08 mm)\
Wear Limit ................................. ( 1) .017" (.43 mm)
( 1) - Specification applies to method obtained by rocking valve stem
in valve guide.









\









\









\









\









\









\









\







CAMSHAFT ( 1)








\









\









\









\









\









\









\







Application In. (mm)\
End Play
3.9L & 5.2L .................................. .002-.010 (.05-.25)\
5.9L ...................................... .002-.010 (.05-.25 mm)\
Camshaft Bearing I.D.
3.9L
No. 1 ................................. 2.000-2.001 (50.80-50.82)\
No. 2 ................................. 1.984-1.985 (50.39-50.42)\
No. 3 ................................. 1.953-1.954 (49.61-49.63)\
No. 4 ................................. 1.563-1.564 (39.70-39.73)\
5.2L & 5.9L
No. 1 ................................. 2.000-2.001 (50.80-50.82)\
No. 2 ................................. 1.984-1.985 (50.39-50.42)\
No. 3 ................................. 1.969-1.970 (50.01-50.04)\
No. 4 ................................. 1.953-1.954 (49.61-49.63)\
No. 5 ................................. 1.563-1.564 (39.70-39.73)\
Journal Diameter
3.9L
No. 1 ................................. 1.998-1.999 (50.75-50.77)\
No. 2 ................................. 1.982-1.983 (50.34-50.37)\
No. 3 ................................. 1.951-1.952 (49.56-49.58)\
No. 4 ................................. 1.561-1.562 (39.65-39.67)\
5.2L & 5.9L

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.









\









\









\









\









\









\









\







CYLINDER BLOCK








\









\









\









\









\









\









\







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)\









\









\









\









\









\









\









\







VALVE LIFTERS








\









\









\









\









\









\









\







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).









\









\









\









\









\









\









\


EN G IN E O VER HAU L P R O CED URES - G EN ER AL IN FO RM ATIO N

1999 D odge P ic ku p R 1500
Engine Overhaul Procedures - General Information
ALL PISTON ENGINES
* PLEASE READ THIS FIRST *
Examples used in this article are general in nature and do
not necessarily relate to a specific engine or system. Illustrations
and procedures have been chosen to guide mechanic through engine
overhaul process. Descriptions of processes of cleaning, inspection,
assembly and machine shop practice are included.
Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and specifications
for the vehicle being repaired.
ENGINE IDENTIFICATION
The engine may be identified from its Vehicle Identification
Number (VIN) stamped on a metal tab. Metal tab may be located in
different locations depending on manufacturer. Engine identification
number or serial number is located on cylinder block. Location varies
with manufacturer.
INSPECTION PROCEDURES
* 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.
GENERAL
Engine components must be inspected to meet manufacturer's
specifications and tolerances during overhaul. Proper dimensions and
tolerances must be met to obtain proper performance and maximum engine
life.
Micrometers, depth gauges and dial indicator are used for
checking tolerances during engine overhaul. Magnaflux, Magnaglo, dye-
check, ultrasonic and x-ray inspection procedures are used for parts
inspection.
MAGNETIC PARTICLE INSPECTION
Magnaflux & Magnaglo
Magnaflux is an inspection technique used to locate material
flaws and stress cracks. The part in question is subjected to a strong
magnetic field. The entire part, or a localized area, can be
magnetized. The part is coated with either a wet or dry material that
contains fine magnetic particles.
Cracks which are outlined by the particles cause an
interruption in the magnetic field. The dry powder method of Magnaflux
can be used in normal light. A crack will appear as an obvious bright
line.
Fluorescent liquid is used in conjunction with a blacklight
in a second Magnaflux system called Magnaglo. This type of inspection
demands a darkened room. The crack will appear as a glowing line in
this process. Both systems require complete demagnetizing upon