2001 DODGE RAM Service Repair Manual

change language sensor handbrake dashboard warning lights climate control TPMS reset

Page 1385 of 2889

DODGE RAM 2001 Service Repair Manual vent corrosion. MopartGasket Sealant is available in
a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assembling parts using a form-in-place gasket
req

vent corrosion. MopartGasket Sealant is available in
a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assembling parts using a form-in-place gasket
requires care but it's easier then using precut gas-
kets.
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
MopartGasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
STANDARD PROCEDUREÐREPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repaired. Essen-
tially, this repair consists of:
²Drilling out worn or damaged threads.
²Tapping the hole with a special Heli-Coil Tap, or
equivalent.
²Installing an insert into the tapped hole to bring
the hole back to its original thread size.
STANDARD PROCEDUREÐHYDROSTATIC
LOCK
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.When an engine is suspected of hydrostatic lock
(regardless of what caused the problem), follow the
steps below.
(1) Disconnect the negative cable(s) from the bat-
tery.
(2) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(3) Place a shop towel around the fuel injectors to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the fuel injectors (Refer
to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL
INJECTOR - REMOVAL).
(4) With all injectors removed, rotate the crank-
shaft using a breaker bar and socket.
(5) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
(6) Be sure all fluid has been removed from the
cylinders.
(7) Repair engine or components as necessary to
prevent this problem from occurring again.
(8) Squirt a small amount of engine oil into the
cylinders to lubricate the walls. This will prevent
damage on restart.
(9) Install new fuel injectors (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/FUEL INJECTOR -
INSTALLATION).
(10) Drain engine oil. Remove and discard the oil
filter (Refer to 9 - ENGINE/LUBRICATION/OIL FIL-
TER - REMOVAL).
(11) Install the drain plug. Tighten the plug to 34
N´m (25 ft. lbs.) torque.
(12) Install a new oil filter (Refer to 9 - ENGINE/
LUBRICATION/OIL FILTER - INSTALLATION).
(13) Fill engine crankcase with the specified
amount and grade of oil (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES - SPECIFICA-
TIONS).
(14) Connect the negative cable(s) to the battery.
(15) Start the engine and check for any leaks.
REMOVALÐENGINE
(1) Disconnect both battery negative cables.
(2) Recover A/C refrigerant (if A/C equipped) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE).
(3) Raise vehicle on hoist.
(4) Drain engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(5) Remove engine oil drain plug and drain engine
oil.
(6) Lower vehicle.
(7) Remove radiator upper hose.
(8) Remove the cooling fan shroud-to-radiator
mounting bolts.
9 - 238 ENGINE 5.9L DIESELBR/BE
ENGINE 5.9L DIESEL (Continued)

Page 1386 of 2889

DODGE RAM 2001 Service Repair Manual (9) Remove viscous fan/drive assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
Remove the cooling fan and shroud together.
(10) Disconnect the coolant recovery bottle hose
from the radiat

(9) Remove viscous fan/drive assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
Remove the cooling fan and shroud together.
(10) Disconnect the coolant recovery bottle hose
from the radiator filler neck and remove bottle from
fan shroud (Fig. 2).
(11) Disconnect heater core supply and return
hoses from the cylinder head fitting and coolant pipe.
(12) Raise vehicle on hoist.
(13) Remove transmission and transfer case (if
equipped.).
(14) Disconnect exhaust pipe from turbocharger
extension pipe (Fig. 3).
(15) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).
(16) Disconnect A/C suction/discharge hose from
the rear of the A/C compressor.
(17) Lower vehicle.
(18) Disconnect lower radiator hose from radiator
outlet.
(19)Automatic Transmission models:Discon-
nect transmission oil cooler lines from radiator using
special tool #6931.
(20) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(21) Remove upper radiator support panel.
(22)
Remove front bumper (Refer to 13 - FRAMES &
BUMPERS/BUMPERS/FRONT BUMPER - REMOVAL).
(23) If A/C equipped, disconnect A/C condenser
refrigerant lines.
(24) Disconnect charge air cooler piping.
(25) Remove the two charge air cooler mounting
bolts.
(26) Remove charge air cooler (and A/C condenser
if equipped) from vehicle.
(27) Disconnect engine block heater connector.
(28) Disconnect A/C compressor electrical connec-
tors.
(29) Remove the passenger battery ground cable
from the engine block.
(30) Disconnect power steering pump pressure and
return lines.
(31) Remove accelerator linkage cover.
(32) Leaving all cables attached, remove accelera-
tor pedal position sensor assy. (APPS) (Fig. 4) from
cylinder head bracket and secure out of the way.
(33) Disconnect APPS connector (Fig. 5).
(34) Disconnect vacuum pump supply hose (Fig. 6).
(35) Disconnect the engine harness and ground
cable from the PDC.
(36) Disconnect the fuel supply and return hoses
(Fig. 7).
(37) Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(38) Remove the #5 and #6 cylinder intake and
exhaust rocker arms and pedestals (Fig. 8). Note the
original location for re-assembly.
(39) Loosen but do not remove engine mount
through bolts and nuts.
(40) Attach chain accross engine lift brackets.
(41)
Lift engine up and out of engine compartment.
(42) Install engine to suitable engine stand.
Fig. 2 Coolant Recovery Bottle
1 - T-SLOTS
2 - ALIGNMENT PIN
3 - FAN SHROUD
4 - COOLANT RESERVE/OVERFLOW TANK
Fig. 3 Exhaust Pipe Connection at Turbocharger
1 - EXHAUST PIPE
2 - TURBOCHARGER EXHAUST PIPE
BR/BEENGINE 5.9L DIESEL 9 - 239
ENGINE 5.9L DIESEL (Continued)

Page 1387 of 2889

DODGE RAM 2001 Service Repair Manual Fig. 4 APPS Assembly
1 - LEVER
2 - MOUNTING BOLTS (6)
3 - WIRE HARNESS CLIP
4 - CALIBRATION SCREWS (NO ADJUSTMENT)
5 - APPS ASSEMBLY
Fig. 5 APPS Connector
1 - APPS
2-TAB
3 - PUSH FOR REMOVAL
4 - APPS

Page 1388 of 2889

DODGE RAM 2001 Service Repair Manual REMOVALÐCRANKCASE BREATHER VAPOR
CANISTER
NOTE: It is recommended to empty the contents of
the vapor canister at each oil and filter service
interval.
(1) Loosen cap from top of vapor canister.
(2) R

REMOVALÐCRANKCASE BREATHER VAPOR
CANISTER
NOTE: It is recommended to empty the contents of
the vapor canister at each oil and filter service
interval.
(1) Loosen cap from top of vapor canister.
(2) Remove nut retaining canister to engine front
cover.
(3) Slide clamp upwards on hose, then remove
hose from crankcase breather.
INSTALLATIONÐENGINE
(1) Install the engine with the cylinder head cover
and the #5 and 6 rocker arm assemblies removed.
(2) Lower the engine into the compartment and
install the engine mount through bolts and nuts.
(3) Tighten the mount through bolts and nuts to
88 N´m (65 ft. lbs.) torque.
(4) Remove the engine lifting device.
(5) Install the #5 and #6 rocker arms and pedes-
tals in their original locations (Fig. 8). Torque the
mounting bolts to 36 N´m (27 ft. lbs.) torque.
(6) Install the cylinder head cover and gasket
(Refer to 9 - ENGINE/CYLINDER HEAD - INSTAL-
LATION).
(7) Connect the fuel supply and return hoses (Fig.
7).
(8) Connect the engine harness connector and
ground cable to the PDC.
(9) Connect the vacuum pump supply hose.(10) Connect the APPS connector (Fig. 5).
(11) Install the APPS assembly bracket to the cyl-
inder head bracket.
(12) Install the throttle linkage cover.
(13) Connect the power steering pressure and
return lines.
(14) Connect the passenger battery ground cable to
the engine block. Tighten the bolt to 77 N´m (57 ft.
lbs.) torque.
(15) Connect the engine block heater connector.
(16) Connect the a/c compressor electrical connec-
tors.
(17) Install the charge air cooler and a/c condenser
(if a/c equipped). Install and tighten the charge air
cooler mounting bolts to 2 N´m (17 in. lbs.) torque.
(18) Connect the charge air cooler piping. Torque
all clamps to 8 N´m (72 in. lbs.) torque.
(19) Connect the a/c refrigerant lines to the a/c
condenser (if equipped).
(20) Install the front bumper (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT
BUMPER - INSTALLATION).
(21) Install the radiator upper support panel.
(22) Install the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION).
Fig. 8 Rocker Arm and PedestalÐRemoval/
Installation
1 - ROCKER ARM
2 - PEDESTALFig. 9 Crankcase Breather Vapor Canister
1 - ENGINE FRONT COVER STUD
2 - STRAP
3 - VAPOR CANISTER
4 - NUT
5 - CAP
6 - CRANKCASE BREATHER
7 - CLAMP
8 - HOSE
BR/BEENGINE 5.9L DIESEL 9 - 241
ENGINE 5.9L DIESEL (Continued)

Page 1389 of 2889

DODGE RAM 2001 Service Repair Manual (23) Connect the transmission quick-connect oil
cooler lines to the radiator. Push together until an
audible ªclickº is heard. Verify connection by pulling
apart.
(24) Raise vehicle.
(25) Connect a/

(23) Connect the transmission quick-connect oil
cooler lines to the radiator. Push together until an
audible ªclickº is heard. Verify connection by pulling
apart.
(24) Raise vehicle.
(25) Connect a/c compressor suction/discharge hose
(if a/c equipped).
(26) Install the radiator lower hose and clamps.
(27) Install the starter motor (Refer to 8 - ELEC-
TRICAL/STARTING/STARTER MOTOR - INSTAL-
LATION).
(28) Install the transmission and transfer case (if
equipped).
(29) Connect the exhaust pipe to the turbocharger
elbow (Fig. 3). Torque the bolts to 34 N´m (25 ft. lbs.)
torque.
(30) Connect the transmission auxiliary oil cooler
lines (if equipped).
(31) Lower the vehicle
(32) Connect the heater core supply and return
hoses.
(33) Install the cooling fan and shroud at the same
time (Refer to 7 - COOLING/ENGINE/RADIATOR
FAN - INSTALLATION).
(34) Install the coolant recovery bottle to the fan
shroud (Fig. 2) and connect the hose to the radiator
filler neck.
(35) Install the windshield washer bottle to the fan
shroud and connect the pump supply hose and elec-
trical connections.
(36) Install the radiator upper hose and clamps.
(37) Change oil filter and install new engine oil.
(38) Fill cooling system with coolant (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(39) Connect battery negative cables.
(40) Perform the fuel line air bleed procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(41) Start engine and inspect for engine oil, cool-
ant, and fuel leaks.
INSTALLATIONÐCRANKCASE BREATHER
VAPOR CANISTER
(1) Position vapor canister with strap over stud on
engine front cover. Install retaining nut. Tighten nut
10 N´m ( 89 in. lbs.).
(2) If removed, position hose onto crankcase
breather, then position clamp.
(3) Position lower portion of hose into vapor canis-
ter, then install and tighten cap.
SPECIFICATIONS
5.9L DIESEL
DESCRIPTION SPECIFICATION
Engine Type In-Line 6 Cyl. Turbo
Diesel
Bore and Stroke 102.0 X 120.0 mm
(4.02 X 4.72 in.)
Displacement 5.9L (359 cu. in.)
Compression Ratio
245 H.P. Version 17.0:1
235 H.P. Version 16.3:1
Horsepower (A/T and 5
Speed M/T)235 @ 2700 rpm
Horsepower (6 Speed M/T
Only)245 @ 2700 rpm
Torque Rating (A/T and 5
Speed M/T)460 ft. lbs. @ 1600 rpm
Torque Rating (6 Speed
M/T Only)505 ft. lbs. @ 1600 rpm
Firing Order 1-5-3-6-2-4
Lubrication System Pressure Feed-Full Flow
With Bypass Valve
Cylinder Block Cast Iron
Crankshaft Induction Hardened
Forged Steel
Cylinder Head Cast Iron With Valve
Seat Inserts
Combustion Chambers High Swirl Bowl
Camshaft Chilled Ductile Iron
Pistons Cast Aluminum
Connecting Rods Cross Rolled Micro Alloy
PISTONS AND CONNECTING RODS
Piston
Skirt Diameter 101.864 ± 101.88 mm
(4.0104 ± 4.011 in.)
Ring Groove Clearance
Intermediate (Max.) 0.095 mm (0.0037 in.)
Oil Control (Max.) 0.085 mm (0.0033 in.)
Piston Pins
Pin Diameter (Min.) 39.990 mm (1.5744 in.)
Bore Diameter (Max.) 40.025 mm (1.5758 in.)
Piston Ring End Gap
Top Ring 0.35 ± 0.45 mm
9 - 242 ENGINE 5.9L DIESELBR/BE
ENGINE 5.9L DIESEL (Continued)

Page 1390 of 2889

DODGE RAM 2001 Service Repair Manual DESCRIPTION SPECIFICATION
(0.014 ± 0.0177 in.)
Intermediate 0.85 ± 1.15 mm
(0.0334 ± 0.0452 in.)
Oil Control 0.250 ± 0.550 mm
(0.010 ± 0.0215 in.)
Connecting Rods
Pin Bore Diameter (Max.) 40.042

Page 1391 of 2889

DODGE RAM 2001 Service Repair Manual SPECIAL TOOLS
5.9L DIESEL ENGINEENGINE DATA PLATE
DESCRIPTION
The engine data plate contains specific information
that is helpful to servicing and obtaining parts for
the engine. The data plate is loc

Page 1392 of 2889

DODGE RAM 2001 Service Repair Manual in air pressure due to an air cleaner element restric-
tion moves the diaphragm and the yellow disc will
indicate the size of the air drop.
CAUTION: Certain engine degreasers or cleaners
may discolor

in air pressure due to an air cleaner element restric-
tion moves the diaphragm and the yellow disc will
indicate the size of the air drop.
CAUTION: Certain engine degreasers or cleaners
may discolor or damage the plastic housing of the
Filter Minder. Cover and tape the Filter Minder if any
engine degreasers or cleaners are to be used.
To test, turn the engine off. If the yellow disc (Fig.
12) has reached the red colored zone on the gradu-
ated scale, the air cleaner element should be
replaced. Refer to the proceeding removal/installation
paragraphs.
Resetting the Filter Minder:After the air
cleaner (filter) element has been replaced, press the
rubber button on the top of the Filter Minder (Fig.
12). This will allow the yellow colored disc to reset.
After the button has been pressed, the yellow disc
should spring back to the UP position.
If the Filter Minder gauge has reached the red col-
ored zone, and after an examination of the air
cleaner (filter) element, the element appears to be
clean, the high reading may be due to a temporary
condition such as snow build-up at the air intake.
Temporary high restrictions may also occur if the air
cleaner (filter) element has gotten wet such as during
a heavy rain or snow. If this occurs, allow the ele-
ment to dry out during normal engine operation.
Reset the rubber button on the top of the Filter
Minder and retest after the element has dried.Removal
(1) Loosen air inlet tube clamp at air cleaner hous-
ing inlet (Fig. 11). Remove this tube at air cleaner
housing cover.
(2) The housing cover is equipped with four (4)
spring clips (Fig. 11) and is hinged at front with plas-
tic tabs. Unlatch clips from top of air cleaner housing
and tilt housing cover up and forward for cover
removal.
(3) Remove air cleaner element from air cleaner
housing.
INSTALLATION
(1) Before installing a new air cleaner element,
clean inside of air cleaner housing.
(2) Position air cleaner cover to tabs on front of air
cleaner housing. Latch four spring clips to seal cover
to housing.
(3) Install air inlet tube at air cleaner housing
inlet. Note hose alignment notches at both inlet hose
and air cleaner cover (Fig. 11).
(4) Position tube clamp to inlet tube and tighten to
3 N´m (25 in. lbs.) torque.
Fig. 11 Filter MinderŸÐLocationÐDiesel Engine
1 - AIR FILTER HOUSING COVER
2 - TURBOCHARGER
3 - AIR INLET TUBE
4 - HOSE CLAMP
5 - HINGE TABS
6 - FILTER MINDER
7 - CLIPS (4)
8 - TUBE ALIGNMENT NOTCHES
Fig. 12 Filter MinderŸÐDiesel Engine
1 - PRESS BUTTON TO RESET
2 - YELLOW DISC
3 - RED ZONE
4 - TO AIR FILTER HOUSING
5 - FILTER MINDER
BR/BEENGINE 5.9L DIESEL 9 - 245
AIR CLEANER ELEMENT (Continued)

Load next 8 pages

Page: < prev 1-10 ... 1353-1360 1361-1368 1369-1376 1377-1384 1385-1392 1393-1400 1401-1408 1409-1416 1417-1424 ... 2896 next >

check engine light wheel torque fuel filter location spark plugs ECU headlight bulb