2001 DODGE RAM clock

CRANKSHAFT OIL SEAL -
REAR
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the transmission and transfer case (if
equipped).
(3) Remove the clutch cover and disc (if manual
transmission equipped) (Refer to 6 - CLUTCH/
CLUTCH DISC - REMOVAL).
(4) Remove the flywheel or converter drive plate.
(5) Drill holes 180É apart into the seal. Be careful
not to contact the drill against the crankshaft.
(6) Install #10 sheet metal screws in the drilled
holes and remove the rear seal with a slide hammer
(Fig. 108).
INSTALLATION
CAUTION: The seal lip and the sealing surface on
the crankshaft must be free from all oil residue to
prevent seal leaks. The crankshaft and seal sur-
faces must be completely dry when the seal is
installed. Use a soap and water solution on outside
diameter of seal to ease assembly.
(1) Clean the crankshaft journal with a suitable
solvent and dry with a clean shop towel or com-
pressed air. Wipe the inside bore of the crankshaft
seal retainer with a clean shop towel.
(2) Inspect the crankshaft journal for gouges,
nicks, or other imperfections. If the seal groove in the
crankshaft is excessively deep, install the new seal
1/8º deeper into the retainer bore, or obtain a crank-shaft wear sleeve that is available in the aftermar-
ket.
(3) Install the seal pilot, provided in the replace-
ment kit, onto the crankshaft.
(4) Using the provided alignment/installation tool,
start the seal over the pilot and into the retainer by
hand.
(5) Using a ball peen hammer, strike the tool at
the 12, 3, 6, and 9 o'clock positions until the align-
ment tool bottoms out on the retainer (Fig. 109).
(6) Remove the seal pilot.
(7) Install the flywheel or converter drive plate.
Tighten the bolts to 137 N´m (101 ft. lbs.) torque.
(8) Install the clutch cover and disc (if equipped)
(Refer to 6 - CLUTCH/CLUTCH DISC - INSTALLA-
TION).
(9) Install the transmission and transfer case (if
equipped).
(10) Lower vehicle.
(11) Connect battery negative cables.
(12) Check engine oil level and adjust, if necessary.
(13) Start engine and check for oil leaks.
CRANKSHAFT REAR OIL SEAL
RETAINER
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
Fig. 108 Crankshaft Rear Seal Removal
1 - NO. 10 SCREW
2 - REAR SEAL
3 - CRANKSHAFT
4 - SLIDE HAMMER
Fig. 109 Seal Installation Using Alignment Tool and
Hammer
1 - SEAL PILOT TOOL
2 - INSTALLATION TOOL
3 - SEAL
4 - RETAINER
9 - 278 ENGINE 5.9L DIESELBR/BE

CAUTION: The seal lip and the sealing surface on
the crankshaft must be free from all oil residue to
prevent seal leaks. The crankshaft and seal sur-
faces must be completely dry when the seal is
installed. Use a soap and water solution on outside
diameter of seal to ease assembly.
(4) Make sure the provided seal pilot is installed
into the new crankshaft seal. Use the alignment/in-
stallation tool and press the seal onto the crankshaft
(Fig. 113). Alternately drive the seal at the 12, 3, 6
and 9 o'clock positions.
(5) Remove the alignment tool and trim the
retainer gasket even with the oil pan mounting sur-
face (Fig. 114).
(6) Remove the seal pilot.
(7) Apply a small amount of MopartSilicone Rub-
ber Adhesive Sealant to the oil pan rail T-joints.
(8) Install the oil pan, suction tube and gaskets
(Refer to 9 - ENGINE/LUBRICATION/OIL PAN -
INSTALLATION).
(9) Install the flywheel housing and bolts. Tighten
the bolts to 60 N´m (44 ft. lbs.) torque.
(10)
Install the starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - INSTALLATION).
(11) Install the flywheel or converter drive plate.
Tighten bolts to 137 N´m (101 ft. lbs.)
(12) Install the transmission and transfer case (if
equipped).
(13) Lower vehicle.
(14) Fill the crankcase with new engine oil.
(15) Connect the battery negative cables.
(16) Start engine and check for oil leaks.
SOLID LIFTERS/TAPPETS
REMOVAL
NOTE: This procedure requires use of Miller Tool
8502 Tappet Replacement Kit, or Cummins Tool Kit
#3822513.
(1) Remove camshaft (Refer to 9 - ENGINE/EN-
GINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - REMOVAL).
(2) Insert the trough (provided with tool kit) the
full length of the camshaft bore (Fig. 115). Make sure
the cap end goes in first and the open side faces up
(towards tappets).
Fig. 115 Inserting the Trough
1 - TROUGH
Fig. 113 Installing Seal Using Alignment Tool and
Hammer
1 - SEAL PILOT TOOL
2 - INSTALLATION TOOL
3 - SEAL
4 - RETAINER
Fig. 114 Trimming Excess Gasket Material
1 - GASKET
9 - 280 ENGINE 5.9L DIESELBR/BE
CRANKSHAFT REAR OIL SEAL RETAINER (Continued)

²If a new cylinder block and/or crankshaft is used,
the piston grading procedureMUST
be performed to
determine the proper piston grade for each cylinder.
(1) Install any of the original connecting rod and
piston assemblies into the No.1 cylinder. DO NOT
install the piston rings.
(2) Install the upper bearing shell in the connect-
ing rod with the tang of the bearing in the slot of the
connecting rod. The connecting rod bearing shell
must be installed in the original connecting rod and
cap. Use clean lubricating oil to coat the inside diam-
eter of the connecting rod bearing shell.
(3) Install the bearing shell in the connecting rod
cap with the tang of the bearing in the slot to the
cap. Use clean lubricating oil to coat the inside diam-
eter of the bearing shell.(4) The four digit number stamped on the connect-
ing rod and cap at the parting line must match and
be installed on the oil cooler side of the engine.
Install the connecting rod cap and cap screws.
Tighten the cap screws to 35 N´m (26 ft. lbs.) torque.
(5) Use a fine grit stone to remove any burrs from
the cylinder block head deck. Zero the dial indicator
to the cylinder block head deck.
(6) Move the dial indicator directly over the piston
pin to eliminate any side-to-side movement.
(7) Rotate the crankshaft to top dead center
(TDC). Rotate the crankshaft clockwise and counter-
clockwise to find the highest dial indicator reading.
Record the reading.
(8)
Remove the piston and connecting rod assembly
from the No.1 cylinder and install the assembly into the
No.2 cylinder. Repeat the procedure for every cylinder
using the same piston and connecting rod assembly.
(9)Determine the grade of the piston being used by
referring to the Piston Protrusion Chart below. Four
digits on top of the piston can be cross referenced to a
DaimlerChrysler part number for replacement (Fig.
126). If the number on the piston cannot be seen, mea-
sure from the top of the piston to the top of the piston
pin to see what grade piston is used (Fig. 127).
NOTE: NEVER INTERMIX PISTONS FROM ONE
ENGINE APPLICATION TO ANOTHER ENGINE
APPLICATION. SEVER DRIVEABILITY CONCERNS
MAY RESULT.
Fig. 124 Piston Ring Identification
Fig. 125 Connecting RodFig. 126 Piston Grading Number Location
BR/BEENGINE 5.9L DIESEL 9 - 283
PISTON & CONNECTING ROD (Continued)

INSTALLATION
(1) Install the plunger, spring, and plug as shown
in (Fig. 152). Tighten the plug to 80 N´m (60 ft. lbs.)
torque.
(2) Connect the battery negative cables.
(3) Start the engine and verify that it has oil pres-
sure.
OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
The 3±wire, solid-state oil pressure sensor is
installed into the oil pressure galley on the engine
block. It is located below and to the rear of the
Engine Control Module (ECM) (Fig. 154).
OPERATION
Operation of the oil pressure sensor on the
diesel engine is controlled by the Engine Con-
trol Module (ECM). The Powertrain Control
Module (PCM) does not have any control over
the sensor.The oil pressure sensor uses three circuits. They
are:
²A 5±volt power supply from the ECM
²A sensor ground through the ECM's sensor
return
²A signal to the ECM relating to engine oil pres-
sure
The oil pressure sensor has a 3±wire electrical
function very much like the Manifold Absolute Pres-
sure (MAP) sensor on the gasoline powered engine.
Meaning different pressures relate to different output
voltages.
A 5±volt supply is sent to the sensor from the ECM
to power up the sensor. The sensor returns a voltage
signal back to the ECM relating to engine oil pres-
sure. This signal is then transferred (bussed) to the
instrument panel on the CCD bus circuit to operate
the oil pressure gauge and the check gauges lamp.
Ground for the sensor is provided by the ECM
through a low-noise sensor return.
REMOVAL
(1) Disconnect the battery negative cables.
(2) Disconnect the oil pressure sensor connector
(Fig. 155).
(3) Using a suitable socket, remove the oil pres-
sure sensor from the block (counter-clockwise).
Fig. 154 Oil Pressure Sensor (Engine) Location
1 - ENGINE OIL PRESSURE SENSOR
2 - ELECTRIAL CONNECTOR
3 - ECM
Fig. 155 Oil Pressure Sensor Location
1 - ENGINE OIL PRESSURE SENSOR
2 - ELECTRIAL CONNECTOR
3 - ECM
9 - 298 ENGINE 5.9L DIESELBR/BE
OIL PRESSURE RELIEF VALVE (Continued)

CAUTION: To prevent pump/gear keyway from fall-
ing into gear housing, engine must be rotated until
keyway is at 12 o'clock position (Fig. 27). If gear
retainer nut, washer or key drops into gear housing,
cover may have to be removed to retrieve them
before engine is started.
Fig. 23 Fuel Supply and Return Lines at Pump
1 - FUEL SUPPLY LINE
2 - FUEL RETURN LINE
3 - BANJO BOLT (TEST PORT FITTING)
4 - OVERFLOW VALVE
5 - BANJO FITTING
Fig. 24 Crankcase Vent Hose
1 - HOSE CLAMP
2 - CRANKCASE VENT HOSE
3 - CRANKCASE BREATHER
Fig. 25 Pump Shaft Nut/Washer
1 - WASHER
2 - PUMP NUT
3 - GEAR COVER
Fig. 26 Rotating Engine with Barring Tool
1 - REAR FLANGE
2 - BARRING TOOL
BR/BEFUEL DELIVERY - DIESEL 14 - 69
FUEL INJECTION PUMP (Continued)

(9) Remove nut and washer retaining injection
pump gear to injection pump shaft (Fig. 25).
(10) The engine can be rotated with a barring tool
such as Snap-On No. SP371, MTE No. 3377371
(Cummins Tool Division), or an equivalent. The open-
ing for barring tool is located in rear flange of engine
on exhaust manifold side (Fig. 26). Remove rubber
access plug covering this opening.
(11) Insert barring tool into flywheel housing open-
ing (Fig. 26).(12) Rotate engine until keyway is at 12 o'clock
position (Fig. 27).
Fig. 27 Placing Keyway at 12 O'clock Position
1 - KEYWAY AT 12 O'CLOCK POSITION
2 - PUMP GEAR
Fig. 28 Separating Injection Pump Gear from Pump
Shaft
1 - T-BAR PULLER
Fig. 29 Rear/Lower Pump Bracket and Mounting
Bolts
1 - FUEL INJECTION PUMP
2 - BOLTS (2)
3 - REAR/LOWER BRACKET
Fig. 30 Injection Pump Mounting Nuts
1 - PUMP MOUNTING NUTS (4)
14 - 70 FUEL DELIVERY - DIESELBR/BE
FUEL INJECTION PUMP (Continued)

(3) The plastic fuel tank module locknut is
threaded onto fuel tank (Fig. 39). Install Special Tool
6856 to locknut and remove locknut (Fig. 49). The
fuel tank module will spring up when locknut is
removed.
(4) Remove module from fuel tank.
INSTALLATION
CAUTION: Whenever the fuel tank module is ser-
viced, the rubber gasket must be replaced.
(1) Thoroughly clean locknut and locknut threads
at top of tank.
(2) Using new gasket, carefully position fuel tank
module into opening in fuel tank.
(3) Position locknut over top of fuel tank module.
Install locknut finger tight.
(4) When looking down at tank from drivers side of
tank, the arrow at top of module should be aligned
between two marks stamped into tank (approximate-
ly 2 o'clock position). The fuel line connectors, roll
over valve and fuel gauge electrical connector should
all be pointed to drivers side of vehicle. Rotate and
align module/tank marks if necessary before tighten-
ing locknut.This step must be performed to pre-
vent the module's float from contacting side of
fuel tank.
(5) Tighten locknut to 24±44 N´m (18±32 ft. lbs.)
torque.
(6) Install fuel tank. Refer to Fuel Tank Removal/
Installation.
FUEL TRANSFER PUMP
DESCRIPTION
The fuel transfer pump (fuel lift pump) is located
on the left-rear side of the engine cylinder block
above the starter motor (Fig. 50). The 12±volt electric
vane-type pump is operated and controlled by the
Engine Control Module (ECM) (Fig. 51).
OPERATION
The purpose of the fuel transfer pump is to supply
(transfer) a low-pressure fuel source:fromthe fuel
tank,throughthe fuel filter/water separator andto
the fuel injection pump. Here, the low-pressure is
raised to a high-pressure by the fuel injection pump
for operation of the high-pressure fuel injectors.
Check valves within the pump, control direction of
fuel flow and prevent fuel bleed-back during engine
shut down.
Normal current flow to the pump is 12 amperes.
With the engine running, the pump has2modes of
operation: Mode 1: 100 percent duty-cycle with a
minimum pressure of 10 psiexcept when the
engine is cranking.Mode 2: 25 percent duty-cycle
with minimum pressure of 7 psiwith the engine
cranking
The 25 percent duty-cycle is used to limit injection
pump inlet pressure until the engine is running.
Fig. 48 Top View of Fuel Tank ModuleÐDiesel
1 - AUXILIARY CAPPED FITTING
2 - FUEL PUMP MODULE
3 - FUEL SUPPLY/RETURN FITTINGS
4 - ELECTRICAL CONNECTOR
5 - LOCKNUT
6 - ROLLOVER VALVE
Fig. 49 Locknut Removal/InstallationÐTYPICAL
MODULE
1 - SPECIAL TOOL 6856
2 - LOCKNUT
BR/BEFUEL DELIVERY - DIESEL 14 - 79
FUEL TANK MODULE (Continued)

COLUMN
TABLE OF CONTENTS
page page
COLUMN
DESCRIPTION............................6
OPERATION.............................6
REMOVAL...............................7
INSTALLATION............................8
SPECIFICATIONS.........................9
KEY-IN IGNITION SWITCH
DESCRIPTION............................9
DIAGNOSIS AND TESTING.................10
IGNITION SWITCH AND KEY LOCK
CYLINDER............................10
LOCK CYLINDER HOUSING
REMOVAL..............................10
INSTALLATION...........................11IGNITION SWITCH
DESCRIPTION...........................11
OPERATION.............................11
DIAGNOSIS AND TESTING.................11
IGNITION SWITCH......................11
REMOVAL..............................12
INSTALLATION...........................12
GEAR SHIFT LEVER
REMOVAL..............................13
INSTALLATION...........................13
STEERING WHEEL
REMOVAL..............................13
INSTALLATION...........................13
COLUMN
DESCRIPTION
The tilt and standard column (Fig. 1) has been
designed to be serviced as an assembly; less wiring,
switches, shrouds, steering wheel, etc. Most steering
column components can be serviced without remov-
ing the steering column from the vehicle.
SERVICE PRECAUTIONS
Safety goggles should be worn at all times when
working on steering columns.
To service the steering wheel, switches or the air-
bag, refer to the WARNINGS and CAUTIONS below.
Fig. 1 Steering Column
1 - STEERING WHEEL
2 - TILT LEVER
3 - UPPER SHROUD
4 - PANEL BRACKET
5 - SPACER
6 - TOE PLATE
7 - NUT
8 - LOWER SHROUD
9 - CLOCK SPRING
10 - NUT
19 - 6 COLUMNBR/BE