2001 DODGE RAM sensor

INSTALLATION...........................34
CRANKSHAFT OIL SEAL - REAR
DESCRIPTION...........................34
OPERATION.............................34
REMOVAL..............................35
INSTALLATION...........................35
DISTRIBUTOR BUSHING
REMOVAL..............................37
INSTALLATION...........................37
HYDRAULIC LIFTERS (CAM IN BLOCK)
DIAGNOSIS AND TESTING.................38
HYDRAULIC TAPPETS...................38
REMOVAL..............................39
CLEANING..............................39
INSTALLATION...........................39
PISTON & CONNECTING ROD
DESCRIPTION...........................40
STANDARD PROCEDURE..................40
PISTON FITTING.......................40
REMOVAL..............................40
CLEANING..............................41
INSPECTION............................41
INSTALLATION...........................41
PISTON RINGS
STANDARD PROCEDURE..................41
PISTON RING FITTING..................41
VIBRATION DAMPER
REMOVAL..............................42
INSTALLATION...........................42
FRONT MOUNT
REMOVAL..............................43
INSTALLATION...........................43
REAR MOUNT
REMOVAL..............................44
INSTALLATION...........................44
LUBRICATION
DESCRIPTION...........................45
OPERATION.............................45
DIAGNOSIS AND TESTING.................47
ENGINE OIL PRESSURE.................47
ENGINE OIL LEAKS.....................47
OIL
STANDARD PROCEDURE..................47
ENGINE OIL...........................47OIL FILTER
REMOVAL..............................48
INSTALLATION...........................48
OIL PAN
REMOVAL..............................48
CLEANING..............................49
INSPECTION............................49
INSTALLATION...........................49
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION...........................49
OPERATION.............................49
OIL PUMP
REMOVAL..............................50
DISASSEMBLY...........................50
CLEANING..............................50
INSPECTION............................50
ASSEMBLY.............................51
INSTALLATION...........................52
INTAKE MANIFOLD
DESCRIPTION...........................52
OPERATION.............................52
DIAGNOSIS AND TESTING.................53
INTAKE MANIFOLD LEAKAGE.............53
REMOVAL..............................53
CLEANING..............................53
INSPECTION............................53
INSTALLATION...........................53
EXHAUST MANIFOLD
DESCRIPTION...........................55
OPERATION.............................55
REMOVAL..............................55
CLEANING..............................55
INSPECTION............................55
INSTALLATION...........................55
TIMING BELT / CHAIN COVER(S)
REMOVAL..............................56
INSTALLATION...........................56
TIMING BELT/CHAIN TENSIONER
DESCRIPTION...........................57
OPERATION.............................57
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL..............................57
INSPECTION............................58
INSTALLATION...........................58
9 - 2 ENGINE 3.9LBR/BE

CLEANING
Clean the block and pan gasket surfaces.
Trim or remove excess sealant film in the rear
main cap oil pan gasket groove.DO NOT remove
the sealant inside the rear main cap slots.
If present, trim excess sealant from inside the
engine.
Clean oil pan in solvent and wipe dry with a clean
cloth.
Clean oil screen and pipe thoroughly in clean sol-
vent. Inspect condition of screen.
INSPECTION
Inspect oil drain plug and plug hole for stripped or
damaged threads. Repair as necessary.
Inspect oil pan mounting flange for bends or distor-
tion. Straighten flange, if necessary.
INSTALLATION
(1) Clean the block and pan gasket surfaces.
(2) Fabricate four alignment dowels from 5/16 X 1
1/2 inch bolts. Cut the head off the bolts and cut a
slot into the top of the dowel. This will allow easier
installation and removal with a screwdriver (Fig. 55).
(3)
Install the dowels in the cylinder block (Fig. 56).
(4) Apply small amount of MopartSilicone Rubber
Adhesive Sealant, or equivalent, in the corner of the
cap and the cylinder block.
(5) Slide the one-piece gasket over the dowels and
onto the block.
(6) Position the oil pan over the dowels and onto
the gasket.
(7) Install the oil pan bolts. Tighten the bolts to 24
N´m (215 in. lbs.) torque.
(8)
Remove the dowels. Install the remaining oil pan
bolts. Tighten these bolts to 24 N´m (215 in. lbs.) torque.
(9) Lower the engine into the support cushion
brackets and tighten the through-bolt nut to the
proper torque.(10) Install the drain plug. Tighten drain plug to
34 N´m (27 ft. lbs.) torque.
(11) Install the engine to transmission strut.
(12) Install exhaust pipe.
(13) Lower vehicle.
(14) Install dipstick.
(15) Connect the negative cable to the battery.
(16) Fill crankcase with oil to proper level.
OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
The 2±wire, electrical/mechanical engine oil pres-
sure sensor (sending unit) is located in an engine oil
pressure gallery.
OPERATION
The oil pressure sensor uses two circuits. They are:
²
A signal to the PCM relating to engine oil pressure
²A sensor ground through the PCM's sensor return
The oil pressure sensor returns a voltage signal
back to the PCM relating to engine oil pressure. This
signal is then transferred (bussed) to the instrument
panel on a CCD bus circuit to operate the oil pres-
sure gauge and the check gauges lamp. Ground for
the sensor is provided by the PCM through a low-
noise sensor return.
Fig. 55 Fabrication of Alignment Dowels
1 - 5/16º X 1óº BOLT
2 - DOWEL
3 - SLOT
Fig. 56 Position of Dowels in Cylinder Block
1 - DOWEL
2 - DOWEL
3 - DOWEL
4 - DOWEL
BR/BEENGINE 3.9L 9 - 49
OIL PAN (Continued)

LUBRICATION
DESCRIPTION..........................292
OPERATION............................292
DIAGNOSIS AND TESTING................295
ENGINE OIL PRESSURE................295
OIL
STANDARD PROCEDURE.................295
ENGINE OIL LEVEL....................295
ENGINE OIL SERVICE..................295
OIL COOLER & LINES
CLEANING.............................296
OIL FILTER
REMOVAL.............................296
INSTALLATION..........................296
OIL PAN
REMOVAL.............................296
CLEANING.............................297
INSPECTION...........................297
INSTALLATION..........................297
OIL PRESSURE RELIEF VALVE
REMOVAL.............................297
CLEANING.............................297
INSPECTION...........................297
INSTALLATION..........................298
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION..........................298OPERATION............................298
REMOVAL.............................298
INSTALLATION..........................299
OIL PUMP
REMOVAL.............................299
CLEANING.............................299
INSPECTION...........................299
INSTALLATION..........................300
INTAKE MANIFOLD
REMOVAL.............................301
CLEANING.............................302
INSPECTION...........................302
INSTALLATION..........................302
EXHAUST MANIFOLD
REMOVAL.............................303
CLEANING.............................304
INSPECTION...........................304
INSTALLATION..........................304
GEAR HOUSING
REMOVAL.............................304
INSTALLATION..........................305
GEAR HOUSING COVER
REMOVAL.............................306
INSTALLATION..........................307
9 - 230 ENGINE 5.9L DIESELBR/BE

CONDITION POSSIBLE CAUSES CORRECTION
4. Turbocharger noise. 4. Check turbocharger impeller and turbine
wheel for housing contact. Repair/replace
as required.
5. Gear train noise. 5. Visually inspect and measure gear
backlash. Replace gears as required.
6. Power function knock. 6. Check/replace rod and main bearings.
DIAGNOSIS AND TESTINGÐSMOKE
DIAGNOSIS CHARTS
The following charts include possible causes and
corrections forexcess or abnormalexhaust smoke.Small amounts of exhaust smoke (at certain times)
are to be considered normal for a diesel powered
engine.
EXCESSIVE BLACK SMOKE
POSSIBLE CAUSE CORRECTION
Air filter dirty or plugged. Check Filter MinderTat air filter (Refer to 9 - ENGINE/
AIR INTAKE SYSTEM/AIR CLEANER ELEMENT -
REMOVAL).
Air intake system restricted. Check entire air intake system including all hoses and
tubes for restrictions, collapsed parts or damage.
Repair/replace as necessary.
Air Leak in Intake System. Check entire air intake system including all hoses and
tubes for cracks, loose clamps and/or holes in rubber
ducts. Also check intake manifold for loose mounting
hardware.
Diagnostic Trouble Codes (DTC's) active or multiple,
intermittent DTC's.Refer to Powertrain Diagnostic Procedures Information.
Engine Control Module (ECM) not calibrated or ECM
has incorrect calibration.Refer to Powertrain Diagnostic Procedures Information.
Exhaust system restriction is above specifications. Check exhaust pipes for damage/restrictions. Repair as
necessary.
Fuel grade is not correct or fuel quality is poor. Temporarily change fuel brands and note condition.
Change brand if necessary.
Fuel injection pump malfunctioning. A DTC should have been set. If so, refer to Powertrain
Diagnostic Procedures Information.
Fuel injector malfunctioning. A DTC should have been set. Perform9Cylinder
Balance Test9using DRB scan tool to isolate individual
cylinders. Also refer to Powertrain Diagnostic
Procedures Information and, to (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/FUEL INJECTOR -
DIAGNOSIS AND TESTING).
Fuel return system restricted. Check fuel return line by checking overflow valve
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
DIAGNOSIS AND TESTING).
Intake manifold restricted. Remove restriction.
Manifold Air Pressure (Boost) Sensor or sensor circuit
malfunctioning.A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
9 - 234 ENGINE 5.9L DIESELBR/BE
ENGINE 5.9L DIESEL (Continued)

EXCESSIVE BLACK SMOKE
POSSIBLE CAUSE CORRECTION
Raw fuel in intake manifold. Fuel injectors leaking on engine shutdown. Do Fuel
Injector Test (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/FUEL INJECTOR - DIAGNOSIS AND
TESTING).
Static timing not correct. A DTC should have been set. If so, refer to Powertrain
Diagnostic Procedures Information. Also (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJECTION
PUMP - DIAGNOSIS AND TESTING).
Turbocharger air intake restriction. Remove restriction.
Turbocharger damaged. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - INSPECTION).
Turbocharger has excess build up on compressor
wheel and/or diffuser vanes.(Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - CLEANING).
Turbocharger wheel clearance out of specification. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - INSPECTION).
EXCESSIVE WHITE SMOKE
POSSIBLE CAUSE CORRECTION
Air in fuel supply: Possible leak in fuel supply side
(between transfer pump and fuel tank module).(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL
TRANSFER PUMP - DIAGNOSIS AND TESTING).
Coolant leaking into combustion chamber. Do pressure test of cooling system (Refer to 7 -
COOLING - DIAGNOSIS AND TESTING).
Diagnostic Trouble Codes (DTC's) active or multiple,
intermittent DTC's.Refer to Powertrain Diagnostic Procedures Information.
In very cold ambient temperatures, engine block heater
is malfunctioning (if equipped).(Refer to 7 - COOLING/ENGINE/ENGINE BLOCK
HEATER - REMOVAL).
Engine coolant temperature sensor malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information. Also check
thermostat operation (Refer to 7 - COOLING/ENGINE/
ENGINE COOLANT THERMOSTAT - DIAGNOSIS AND
TESTING).
Engine Control Module (ECM) not calibrated or has
incorrect calibration.A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Fuel filter plugged. Perform Fuel Pressure Drop Test (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL TRANSFER PUMP -
DIAGNOSIS AND TESTING).
Fuel grade not correct or fuel quality is poor. Temporarily change fuel brands and note condition.
Change brand if necessary.
Fuel heater element or fuel heater temperature sensor
malfunctioning. This will cause wax type build-up in fuel
filter.Refer to Fuel Heater Testing (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL HEATER -
DIAGNOSIS AND TESTING).
Fuel injector malfunctioning. A DTC should have been set. Perform9Cylinder
Balance Test9using DRB scan tool to isolate individual
cylinders. Also refer to Powertrain Diagnostic
Procedures Information and, (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/FUEL INJECTOR -
DIAGNOSIS AND TESTING).
Fuel injector hold-downs loose. Torque to specifications.
BR/BEENGINE 5.9L DIESEL 9 - 235
ENGINE 5.9L DIESEL (Continued)

EXCESSIVE WHITE SMOKE
POSSIBLE CAUSE CORRECTION
Fuel injector protrusion not correct. Check washer (shim) at bottom of fuel injector for
correct thickness. (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/FUEL INJECTOR - INSTALLATION)
Fuel injection pump malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Fuel supply side restriction to transfer pump. Refer to Fuel Transfer Pump Pressure (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL TRANSFER
PUMP - DIAGNOSIS AND TESTING)
Fuel transfer (lift) pump malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information. Also refer to Fuel
Transfer Pump Pressure Testing (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL TRANSFER PUMP -
DIAGNOSIS AND TESTING).
Intake/Exhaust valve adjustments not correct (too tight). (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/
EXHAUST VALVES & SEATS - STANDARD
PROCEDURE).
Intake manifold air temperature sensor malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Intake manifold heater circuit not functioning correctly in
cold weather.A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information. Also check heater
elements for correct operation.
Intake manifold heater elements not functioning
correctly in cold weather.A diagnostic trouble code WILL NOT BE SET if heater
elements are malfunctioning. Refer to NTC tests in
Powertrain Diagnostic Procedures Information.
Internal engine damage (scuffed cylinder). Analyze engine oil and inspect oil filter to locate area of
probable damage.
Restriction in fuel supply side of fuel system. Refer to Fuel Transfer Pump Pressure Testing (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL
TRANSFER PUMP - DIAGNOSIS AND TESTING).
Static timing incorrect. A DTC should have been set. If so, (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJECTION
PUMP - DIAGNOSIS AND TESTING).
EXCESSIVE BLUE SMOKE
POSSIBLE CAUSE CORRECTION
Dirty air cleaner or restricted turbocharger intake duct. Check Filter MinderTat air filter housing. (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
ELEMENT - REMOVAL).
Air leak in boost system between turbocharger
compressor outlet and intake manifold.Service air charge system..
Obstruction in exhaust manifold. Remove exhaust manifold and inspect for blockage
(Refer to 9 - ENGINE/MANIFOLDS/EXHAUST
MANIFOLD - REMOVAL).
Restricted turbocharger drain tube. Remove turbocharger drain tube and remove
obstruction.
Crankcase ventilation system plugged. Inspect crankcase breather and vent tube for sludge
formation or obstructions.
9 - 236 ENGINE 5.9L DIESELBR/BE
ENGINE 5.9L DIESEL (Continued)

(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)

CYLINDER HEAD
DESCRIPTION
The cylinder head (Fig. 13) is constructed of cast
iron and is a one piece cross flow design with four
valves per cylinder. The arrangement of two intake
and two exhaust valves per cylinder allows for a cen-
trally located injector. The cylinder head also
includes an integral intake manifold, an integral
thermostat housing, and a longitudal fuel return
rifle, which exits at the rear of the head. The 24
valve design also includes integrally cast valve
guides and hardened intake and exhaust valve seat
inserts.
REMOVAL
(1) Disconnect battery negative cables.
(2) Raise vehicle on hoist.
(3) Drain engine coolant.
(4) Disconnect exhaust pipe from turbocharger
elbow (Fig. 14).
(5) Lower vehicle.
(6) Remove air cleaner housing and snorkel from
the vehicle. Cap off turbocharger air inlet to prevent
intrusion of dirt or foreign material.
(7) Disconnect cab heater core supply and return
hoses from the cylinder head and heater pipe.
(8) Disconnect turbocharger oil drain tube at rub-
ber hose connection. Cap off open ports to prevent
intrusion of dirt or foreign material.
(9) Disconnect turbocharger oil supply line at the
turbocharger end. Cap off open ports to prevent
intrusion of dirt or foreign material.
(10) Remove exhaust manifold-to-cylinder head
bolts and spacers. Remove exhaust manifold and tur-
bocharger from the vehicle as an assembly.
(11) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(12) Remove generator upper bracket.
(13) Disconnect radiator upper hose from the ther-
mostat housing.
(14) Disconnect the coolant temperature sensor
connector.
(15) Remove the engine harness to cylinder head
attaching bolt at front of head.
(16) Remove the engine harness ground fastener
at front of head below the thermostat housing.
Fig. 13 Cylinder Head and Gasket
1 - THERMOSTAT BORE
2 - INTAKE RUNNER
3 - CYLINDER HEAD
4 - CYLINDER HEAD GASKET
5 - CYLINDER BLOCK
Fig. 14 Exhaust Pipe-to-Turbocharger Elbow
1 - EXHAUST PIPE
2 - TURBOCHARGER EXHAUST PIPE
9 - 246 ENGINE 5.9L DIESELBR/BE