2001 DODGE RAM intake

DESCRIPTION SPECIFICATION
Bearing Clearance
Journal #1 0.013 ± 0.038 mm
(0.0005 ± 0.0015 in.)
Journals#2-50.013 ± 0.051 mm
(0.0005 ± 0.002 in.)
Service Limit
Journal #1 0.0381 mm (0.0015 in.)
Journals #2-5 0.064 mm (0.0025 in.)
Crankshaft End Play 0.051 ± 0.178 mm
(0.002 ± 0.007 in.)
Service Limit 0.254 mm (0.010 in.)
CYLINDER BLOCK
Cylinder Bore
Diameter 101.60 ± 101.65 mm
(4.000 ± 4.002 in.)
Out of Round (Max.) 0.0254 mm (0.001 in.)
Taper (Max.) 0.0254 mm (0.001 in.)
Lifter Bore
Diameter 22.99 ± 23.01 mm
(0.9051 ± 0.9059 in.)
Distributor Drive Bushing
Press Fit
Bushing to Bore
Interference0.0127 ± 0.3556 mm
(0.0005 ± 0.0140 in.)
Shaft to Bushing
Clearance0.0178 ± 0.0686 mm
(0.0007 ± 0.0027 in.)
CYLINDER HEAD AND VALVES
Valve Seat
Angle 44.25É ± 44.75É
Runout (Max.) 0.0762 mm (0.003 in.)
Width (Finish)
Intake 1.016 ± 1.524 mm
(0.040 ± 0.060 in.)
Exhaust 1.524 ± 2.032 mm
(0.060 ± 0.080 in.)DESCRIPTION SPECIFICATION
Valves
Face Angle 43.25É ± 43.75É
Head Diameter
Intake 47.752 mm (1.88 in.)
Exhaust 41.072 (1.617 in.)
Length (Overall)
Intake 126.21 ± 126.85 mm
(4.969 ± 4.994 in.)
Exhaust 126.44 ± 127.30 mm
(4.978 ± 5.012 in.)
Lift (@ zero lash)
Intake 10.414 mm (0.410 in.)
Exhaust 10.592 mm (0.417 in.)
Stem Diameter
Intake 9.449 ± 9.474 mm
(0.372 ± 0.373 in.)
Exhaust 9.423 ± 9.449 mm
(0.371 ± 0.372 in.)
Guide Bore 9.500 ± 9.525 mm
(0.374 ± 0.375 on.)
Stem to Guide Clearance
Intake 0.0254 ± 0.0762 mm
(0.001 ± 0..003 in.)
Exhaust 0.0508 ± 0.1016 mm
(0.002 ± 0.004 in.)
Service Limit 0.4318 (0.017 in.)
Valve Springs
Free Length 49.962 mm (1.967 in.)
Spring Tension
Valve closed 378 N @ 41.66 mm
(85 lbs. @ 1.64 in.)
Valve open 890 N @ 30.89 mm
(200 lbs. @ 1.212 in.)
Number of Coils 6.8
Installed Height 41.66 mm (1.64 in.)
Wire Diameter 4.50 mm (0.177 in.)
9 - 130 ENGINE 5.9LBR/BE
ENGINE 5.9L (Continued)

DESCRIPTION SPECIFICATION
VALVE TIMING
Exhaust Valve
Closes (ATDC) 33É
Opens (BBDC) 56É
Duration 269É
Intake Valve
Closes (ATDC) 62É
Opens (BBDC) 7É
Duration 249É
Valve Overlap 41ÉOVERSIZE AND UNDERSIZE ENGINE
COMPONENT MARKINGS CHART
OS-US Item Identification Location of
Identification
U/S Crankshaft R or M M-2-3
ect.Milled flat on
.025 MM (indicating No.
2&No. three
(.001
IN.)3 main bearing crankshaft
journal) and/or counterweight.
R-1-4 ect.
(indicating No.
1&
4 connecting
rod
journal)
O/S Cylinder A Following
.508 mm Bores engine serial
(.020 in.) number.
O/S TappetsL3/89
.203 mm diamound
(.008 in.) -shaped
stamp Top
pad
Ð Front of
engine and
flat
ground on
outside
surface
of each O/S
tappet bore.
O/S Valve
StemsX Milled pad
.127 mm adjacent to
two
(0.005
in.)3/89tapped
holes on
each
end of
cylinder
head.
9 - 132 ENGINE 5.9LBR/BE
ENGINE 5.9L (Continued)

TORQUE
TORQUE CHART 5.9L ENGINE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Camshaft SprocketÐBolt 68 50 Ð
Camshaft Thrust PlateÐBolts 24 Ð 210
Timing Chain Case CoverÐ
Bolts41 30 Ð
Connecting Rod CapÐBolts 61 45 Ð
Main Bearing CapÐBolts 115 85 Ð
Crankshaft PulleyÐBolts 24 Ð 210
Cylinder HeadÐBolts
Step 1 68 50 Ð
Step 2 143 105 Ð
Cylinder Head CoverÐBolts 11 Ð 95
Engine Support Bracket to
BlockÐ41 30 Ð
Bolts (4WD)
Exhaust Manifold to Cylinder
HeadÐ34 25 Ð
Bolts/Nuts
FlywheelÐBolts 75 55 Ð
Front InsulatorÐThrough
bolt/nut95 70 Ð
Front Insulator to Support
Bracket
ÐStud Nut (4WD) 41 30 Ð
ÐThrough Bolt/Nut (4WD) 102 75 Ð
Front Insulator to BlockÐ
Bolts (2WD)95 70 Ð
GeneratorÐMounting Bolt 41 30 Ð
Intake ManifoldÐBolts Refer to Procedure
Oil PanÐBolts 24 Ð 215
Oil PanÐDrain Plug 34 25 Ð
Oil PumpÐAttaching Bolts 41 30 Ð
Oil Pump CoverÐBolts 11 Ð 95
Rear Insulator to BracketÐ 68 50 Ð
Through-Bolt (2WD)
Rear Insulator to
Crossmember41 30 Ð
Support BracketÐNut (2WD)
Rear Insulator to
CrossmemberÐ68 50 Ð
Nuts (4WD)
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Rear Insulator to
TransmissionÐ68 50 Ð
Bolts (4WD)
Rear Insulator BracketÐBolts 68 50 Ð
(4WD Automatic)
Rear Support Bracket to 41 30 Ð
Crossmember FlangeÐNuts
Rear Support Plate to
Transfer41 30 Ð
CaseÐBolts
Rocker ArmÐBolts 28 21 Ð
Spark Plugs 41 30 Ð
Starter MotorÐMounting Bolts 68 50 Ð
Thermostat HousingÐBolts 25 Ð 225
Throttle BodyÐBolts 23 Ð 200
Torque Converter Drive
PlateÐBolts31 Ð 270
Transfer Case to Insulator 204 105 Ð
Mounting PlateÐNuts
Transmission Support
BracketÐ68 50 Ð
Bolts (2WD)
Vibration DamperÐBolt 244 180 Ð
Water Pump to Timing Chain 41 30 Ð
Case CoverÐBolts
BR/BEENGINE 5.9L 9 - 133
ENGINE 5.9L (Continued)

CYLINDER HEAD
DESCRIPTIONÐCYLINDER HEAD
The cast iron cylinder heads (Fig. 4) are mounted
to the cylinder block using ten bolts. The spark plugs
are located in the peak of the wedge between the
valves.
DESCRIPTIONÐCYLINDER HEAD COVER
GASKET
The cylinder head cover gasket (Fig. 5) is a steel-
backed silicone gasket, designed for long life usage.
OPERATIONÐCYLINDER HEAD
The cylinder head closes the combustion chamber
allowing the pistons to compress the air fuel mixture to
the correct ratio for ignition. The valves located in the
cylinder head open and close to either allow clean airinto the combustion chamber or to allow the exhaust
gases out, depending on the stroke of the engine.
OPERATION
The steel-backed silicone gasket is designed to seal
the cylinder head cover for long periods of time
through extensive heat and cold, without failure. The
gasket is designed to be reusable.
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET FAILURE
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
²Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
²Loss of engine power
²Engine misfiring
²Poor fuel economy
²Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
²Engine overheating
²Loss of coolant
²Excessive steam (white smoke) emitting from
exhaust
²Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test in this
section. An engine cylinder head gasket leaking
between adjacent cylinders will result in approxi-
mately a 50±70% reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Fig. 4 Cylinder Head AssemblyÐV-8 Gas Engines
1 - EXHAUST VALVE
2 - SPARK PLUGS
3 - EXHAUST VALVES
4 - SPARK PLUGS
5 - EXHAUST VALVE
6 - INTAKE VALVES
7 - INTAKE VALVES
Fig. 5 Cylinder Head Cover Gasket V-8 Gas Engines
1 - CYLINDER HEAD COVER GASKET
9 - 136 ENGINE 5.9LBR/BE

Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3)
Remove the air cleaner resonator and duct work.
(4) Remove the intake manifold-to-generator
bracket support rod. Remove the generator.
(5) Remove closed crankcase ventilation system.
(6) Disconnect the evaporation control system.
(7) Perform the Fuel System Pressure Release pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY - STANDARD PROCEDURE). Disconnect the
fuel supply line (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(8) Disconnect accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(9) Remove distributor cap and wires.
(10) Disconnect the coil wires.
(11) Disconnect heat indicator sending unit wire.
(12) Disconnect heater hoses and bypass hose.
(13) Remove cylinder head covers and gaskets
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(14)
Remove intake manifold (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - REMOVAL) and
throttle body as an assembly. Discard the flange side
gaskets and the front and rear cross-over gaskets.
(15) Remove exhaust manifolds (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
REMOVAL).
(16) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations.
(17) Remove the head bolts from each cylinder
head and remove cylinder heads. Discard the cylin-
der head gasket.
(18) Remove spark plugs.
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
INSPECTION
Inspect all surfaces with a straightedge if there is
any reason to suspect leakage. If out-of-flatness
exceeds 0.00075mm/mm (0.0001in./in.) times the
span length in any direction, either replace head or
lightly machine the head surface.
FOR EXAMPLE:ÐA 305 mm (12 in.) span is
0.102 mm (0.004 in.) out-of-flat. The allowable out-of-
flat is 305 x 0.00075 (12 x 0.00075) equals 0.23 mm
(0.009 in.). This amount of out-of-flat is acceptable.
The cylinder head surface finish should be
1.78-3.00 microns (70-125 microinches).
Inspect push rods. Replace worn or bent rods.
INSTALLATION
(1) Clean all surfaces of cylinder block and cylin-
der heads.
(2) Clean cylinder block front and rear gasket sur-
faces using a suitable solvent.
(3) Position new cylinder head gaskets onto the
cylinder block.
(4) Position cylinder heads onto head gaskets and
cylinder block.
(5) Starting at top center, tighten all cylinder head
bolts, in sequence (Fig. 6).
CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
TDC. Contact between the valves and piston could
occur.
(6) Install push rods and rocker arm assemblies in
their original position. Tighten the bolts to 28 N´m
(21 ft. lbs.) torque.
(7) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION) and throttle body assembly.
(8) Install exhaust manifolds (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
INSTALLATION).
Fig. 6 Cylinder Head Bolt Tightening Sequence
BR/BEENGINE 5.9L 9 - 137
CYLINDER HEAD (Continued)

(9) If required, adjust spark plugs to specifications.
Install the plugs and tighten to 41 N´m (30 ft. lbs.)
torque.
(10) Install coil wire.
(11) Connect heat indicator sending unit wire.
(12) Connect the heater hoses and bypass hose.
(13) Install distributor cap and wires.
(14) Connect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(15) Install the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(16) Install the generator and drive belt (Refer to 7
- COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION). Tighten generator mounting bolt
to 41 N´m (30 ft. lbs.) torque. Tighten the adjusting
strap bolt to 23 N´m (200 in. lbs.) torque.
(17) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts.
(18) Place the cylinder head cover gaskets in posi-
tion and install cylinder head covers (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(19) Install closed crankcase ventilation system.
(20) Connect the evaporation control system.
(21) Install the air cleaner.
(22) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(23) Connect the negative cable to the battery.
(24) Start engine check for leaks.
CYLINDER HEAD COVER(S)
REMOVAL
NOTE: A steel backed silicon gasket is used with
the cylinder head cover (Fig. 7). This gasket can be
used again.
(1) Disconnect the negative cable from the battery.(2) Disconnect the spark plug wires form the spark
plugs and set aside.
(3) Disconnect closed ventilation system and evap-
oration control system from cylinder head cover.
(4) Remove cylinder head cover and gasket.
CLEANING
Clean cylinder head cover gasket surface.
Clean head rail, if necessary.
INSPECTION
Inspect cover for distortion and straighten, if nec-
essary.
Check the gasket for use in head cover installation.
If damaged, use a new gasket.
INSTALLATION
(1) The cylinder head cover gasket can be used
again. Install the gasket onto the head rail.
(2) Position the cylinder head cover onto the gas-
ket. Tighten the bolts to 11 N´m (95 in. lbs.) torque.
(3) Install closed crankcase ventilation system and
evaporation control system.
(4)
Connect the spark plug wires to the spark plugs.
(5) Connect the negative cable to the battery.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
Both the intake and exhaust valves are made of
steel. The intake valve is 48.768 mm (1.92 inches) in
diameter and the exhaust valve is 41.148 mm (1.62
inches) in diameter and has a 2.032 mm (0.080 inch)
wafer interia welded to the tip for durability. These
valves are not splayed.
STANDARD PROCEDUREÐVALVES, GUIDES
AND SPRINGS
VALVE CLEANING
Clean valves thoroughly. Discard burned, warped,
or cracked valves.
Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner.
VALVE GUIDES
Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 in.), replace the valve.
Measure valve stem guide clearance as follows:
(1) Install Valve Guide Sleeve Tool C-3973 over
valve stem and install valve (Fig. 8). The special
sleeve places the valve at the correct height for
checking with a dial indicator.
Fig. 7 Cylinder Head Cover Gasket
1 - CYLINDER HEAD COVER GASKET
9 - 138 ENGINE 5.9LBR/BE
CYLINDER HEAD (Continued)

(2) Attach dial indicator Tool C-3339 to cylinder
head and set it at right angles to valve stem being
measured (Fig. 9).
(3) Move valve to and from the indicator. The total
dial indicator reading should not exceed 0.432 mm
(0.017 in.). Ream the guides for valves with oversize
stems if dial indicator reading is excessive or if the
stems are scuffed or scored.
VALVE GUIDES
Service valves with oversize stems are available.
Refer to REAMER SIZES CHART
REAMER SIZES CHART
REAMER O/S VALVE GUIDE SIZE
0.076 mm 8.026 - 8.052 mm
(0.003 in.) (0.316 - 0.317 in.)
0.381 mm 8.331 - 8.357 mm
(0.015 in.) (0.328 - 0.329 in.)(1)
Slowly turn reamer by hand and clean guide thor-
oughly before installing new valve.Ream the valve
guides from standard to 0.381 mm (0.015 in.). Use
a two step procedure so the valve guides are
reamed true in relation to the valve seat:
²Step 1ÐReam to 0.0763 mm (0.003 inch).
²Step 2ÐReam to 0.381 mm (0.015 inch).
REFACING VALVES AND VALVE SEATS
The intake and exhaust valves have a 43-1/4É to
43-3/4É face angle and a 44-1/4É to 44-3/4É seat angle
(Fig. 10).
VALVE FACE AND VALVE SEAT ANGLE CHART
ITEM DESCRIPTION SPECIFICATION
ASEAT WIDTH
INTAKE 1.016 - 1.524 mm
(0.040 - 0.060 in.)
EXHAUST 1.524 - 2.032 mm
(0.060 - 0.080 in.)
BFACE ANGLE
(INT. AND EXT.) 43òÉ - 43ôÉ
CSEAT ANGLE
(INT. AND EXT.) 44òÉ - 44ôÉ
DCONTACT
SURFACE Ð
Fig. 8 Positioning Valve with Tool C-3973
1 - VALVE
2 - SPACER TOOL
Fig. 9 Measuri2ng Valve Guide Wear
1 - VALVE
2 - SPECIAL TOOL C-3339
Fig. 10 Valve Face and Seat Angles
1 - CONTACT POINT
A,B,C and D Refer to VALVE FACE AND VALVE SEAT ANGLE
CHART
BR/BEENGINE 5.9L 9 - 139
INTAKE/EXHAUST VALVES & SEATS (Continued)

VALVES
Inspect the remaining margin after the valves are
refaced (Fig. 11). Valves with less than 1.190 mm
(0.047 in.) margin should be discarded.
VALVE SEATS
CAUTION: DO NOT un-shroud valves during valve
seat refacing (Fig. 12).(1) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-
ing stones. A true and complete surface must be
obtained.
(2) Measure the concentricity of valve seat using a
dial indicator. Total runout should not exceed 0.051
mm (0.002 in.) total indicator reading.
(3) Inspect the valve seat with Prussian blue, to
determine where the valve contacts the seat. To do
this, coat valve seat LIGHTLY with Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is trans-
ferred to the top edge of valve face, lower valve seat
with a 15É stone. If the blue is transferred to bottom
edge of valve face raise valve seat with a 60É stone.
(4) When seat is properly positioned the width of
intake seats should be 1.016-1.524 mm (0.040-0.060
in.). The width of the exhaust seats should be 1.524-
2.032 mm (0.060-0.080 in.).
VALVE SPRINGS
Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested. As an example the compression length of
the spring to be tested is 1-5/16 in.. Turn table of
Universal Valve Spring Tester Tool until surface is in
line with the 1-5/16 in. mark on the threaded stud.
Be sure the zero mark is to the front (Fig. 13). Place
spring over stud on the table and lift compressing
lever to set tone device. Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by 2. This will give the
spring load at test length. Fractional measurements
are indicated on the table for finer adjustments.
Refer to specifications to obtain specified height and
allowable tensions. Discard the springs that do not
meet specifications.
REMOVAL
(1) Remove the cylinder head (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(2) Compress valve springs using Valve Spring
Compressor Tool MD- 998772A and adapter 6716A.
(3) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(4) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
valve guides. Identify valves to ensure installation in
original location.
CLEANING
Clean valves thoroughly. Discard burned, warped,
or cracked valves.
Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner.
Fig. 11 Intake and Exhaust Valves
1 - MARGIN
2 - VALVE SPRING RETAINER LOCK GROOVE
3 - STEM
4-FACE
Fig. 12 Refacing Valve Seats
1-STONE
2 - PILOT
3 - VALVE SEAT
4 - SHROUD
9 - 140 ENGINE 5.9LBR/BE
INTAKE/EXHAUST VALVES & SEATS (Continued)