2001 DODGE RAM light

Set up a boring bar and machine the sleeve to
101.956 mm (4.014 inch) - (Fig. 77).
After removing the boring bar, use a honing stone
to chamfer the corner of the repair sleeve(s) - (Fig.
77).
SLEEVE MACHINING DIMENSIONS CHART
ITEM MEASUREMENT
SLEEVE PROTRUSION MIN. - FLUSH WITH
BLOCK
MAX. - 0.050 mm
(0.0019 in.)
SLEEVE DIAMETER 101.956 mm (4.014 in.)
SLEEVE CHAMFER APPROX. 1.25 mm
(0.049 in.) by 15É
A correctly honed surface will have a crosshatch
appearance with the lines at 15É to 25É angles with
the top of the cylinder block. For the rough hone, use
80 grit honing stones. To finish hone, use 280 grit
honing stones.
Finished bore inside dimension is 102.020  0.020
mm (4.0165  0.0008 inch).
A maximum of 1.2 micrometer (48 microinch) sur-
face finish must be obtained.
After finish honing is complete, immediately clean
the cylinder bores with a strong solution of laundry
detergent and hot water.
After rinsing, blow the block dry with compressed
air.
Wipe the bore with a white, lint-free, lightly oiled
cloth. Make sure there is no grit residue present.
Apply a rust-preventing compound if the block will
not be used immediately.
A standard diameter piston and a piston ring set
must be used with a sleeved cylinder bore.
STANDARD PROCEDUREÐCAM BORE REPAIR
The front cam bushing bore can be bored to 59.235
Mm  0.013 mm (2.332 inch  0.0006 inch) oversize.
DO NOT bore the intermediate or rear cam bore to
the front cam bore oversize dimensions. Intermediate
and rear cam bores may be bored to 57.235 mm
 0.013 mm (2.253 inch  0.0006± inch) oversize.
A surface finish of 2.3 micrometers (92 microinch)
must be maintained. Not more than 20% of an area
of any one bore may be 3.2 micrometers (126 micro-
inch).
Camshaft bores can be repaired individually. It is
not necessary to repair undamaged cam bores in
order to repair individually damaged cam bores. The
standard front bushing cannot be used to repair
intermediate or rear bores.
Install all cam bushings flush or below the front
cam bore surface. The oil hole must align to allow a
3.2 mm (0.125 inch) rod to pass through freely (Fig.
78).
INSPECTION
Measure the combustion deck face using a straight
edge and a feeler gauge (Fig. 79). The distortion of
the combustion deck face is not to exceed 0.010 mm
(0.0004 inch) in any 50.00 mm (2.0 inch) diameter.
Overall variation end to end or side to side is 0.075
mm (0.003 inch).
If the surface exceeds the limit,.
Inspect the cylinder bores for damage or excessive
wear.
Measure the cylinder bores (Fig. 80). If the cylin-
der bores exceeds the limit, (Refer to 9 - ENGINE/
ENGINE BLOCK - STANDARD PROCEDURE).
Inspect the camshaft bores for scoring or excessive
wear.
Measure the camshaft bores (Refer to 9 - ENGINE
- SPECIFICATIONS). Limit for the No.1 bore applies
to the ID of the bushing.
If a bore exceeds the limit, (Refer to 9 - ENGINE/
ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - STANDARD PROCEDURE).
Fig. 77 Sleeve Machining Dimensions
1 - DIAMETER
2 - PROTRUSION
3 - CHAMFER
Fig. 78 Oil Hole Alignment
1 - CAMSHAFT BUSHING
BR/BEENGINE 5.9L DIESEL 9 - 267
ENGINE BLOCK (Continued)

(3) Remove the oil pan drain plug and drain the
engine oil. Re-install plug and torque to 60 N´m (44
ft. lbs.) torque.
(4) Remove transmission and transfer case (if
equipped) from vehicle.
(5) Remove flywheel or torque converter drive
plate.
(6) Disconnect starter cables from starter motor.
(7) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
and transmission adapter plate assembly.
(8) Disconnect cables from starter motor.
(9) Remove the eight flywheel housing to block
bolts and remove housing and starter motor as an
assembly.
(10) Remove oil pan bolts, break the pan to block
seal, and lower pan slightly and remove oil suction
tube fasteners.
(11) Remove oil pan and suction tube (Fig. 110)
(Refer to 9 - ENGINE/LUBRICATION/OIL PAN -
REMOVAL).
(12) Remove the six (6) retainer-to-block bolts (Fig.
111).
(13) Remove the rear seal retainer and gasket
(Fig. 111).
(14) Support the seal retainer and drive out the
crankshaft seal with a hammer and suitable punch.
INSTALLATION
(1) If using the old seal retainer, it is recom-
mended that the crankshaft seal is replaced. Support
the seal retainer and drive out the old seal.
(2) Using the retainer alignment/seal installation
tool provided in the seal service kit, install the align-
ment tool into the retainer and install to the cylinder
block (Fig. 112), using a new gasket. Tighten the six
(6) mounting bolts by hand.
(3) Starting with the center two bolts, tighten the
retainer in a circular pattern to 9 N´m (80 in. lbs.).
Remove the alignment tool.
Fig. 110 Oil Pan, Suction Tube and Gasket
1 - GASKET
2 - SUCTION TUBE
3 - OIL PAN
Fig. 111 Crankshaft Rear Seal Retainer and Gasket
1 - RETAINER
2 - GASKET
3 - BOLT
Fig. 112 Aligning Seal Retainer with Alignment/
Installation Tool
1 - ALIGNMENT / INSTALLATION TOOL
2 - SEAL RETAINER
BR/BEENGINE 5.9L DIESEL 9 - 279
CRANKSHAFT REAR OIL SEAL RETAINER (Continued)

FRONT MOUNT
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the viscous fan/drive assembly (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
(3) Raise vehicle on hoist.
(4) Support engine with a screw jack and wood
block.
(5) Loosen the thru-bolt and nut (Fig. 145).
(6) Passenger side mount: Remove the two (2)
transmission oil cooler bracket to engine mount bolts.
(7) Lift the engine SLIGHTLY and remove the four
(4) mount to block bolts.
(8) Remove the mount from the vehicle.
INSTALLATION
(1) With engine raised SLIGHTLY, position the
engine mount to the block. Install the bolts and
tighten to 149 N´m (110 ft. lbs.) torque.
(2) Install the thru-bolt into the engine mount.
(3) Lower the engine while guiding the mount and
thru-bolt into the frame mounted support cushion
brackets (Fig. 146).
(4) Install the thru-bolt nut and tighten the nut to
88 N´m (65 ft. lbs.) torque.
(5) Passenger side: Install the two (2) transmission
oil cooler bracket to mount bolts. Tighten the bolts to
47 N´m (35 ft. lbs.) torque.
(6) Remove lifting fixture.
(7) Lower the vehicle.
(8) Install the viscous fan/drive assembly (Refer to
7 - COOLING/ENGINE/RADIATOR FAN - INSTAL-
LATION).
(9) Connect the battery negative cables.
Fig. 145 Front Engine MountÐTypical
1 - MOUNT
2 - BOLT (4)
Fig. 146 Positioning Engine Front Mounts
1 - ENGINE SUPPORT BRACKET/CUSHION
2 - SUPPORT CUSHION BRACKET
9 - 290 ENGINE 5.9L DIESELBR/BE

REAR MOUNT
REMOVAL
(1) Raise the vehicle on a hoist.
(2) Position a transmission jack in place.
(3) Remove support cushion stud nuts (Fig. 147).
(4) Raise rear of transmission and engine
SLIGHTLY.
(5) Remove the bolts holding the support cushion
to the transmission support bracket. Remove the sup-
port cushion.
(6) If necessary, remove the bolts holding the
transmission support bracket to the transmission.
INSTALLATION
(1) If removed, position the transmission support
bracket to the transmission. Install new attaching
bolts and tighten to 102 N´m (75 ft. lbs.) torque.
(2) Position support cushion to transmission sup-
port bracket. Install stud nuts and tighten to 47 N´m
(35 ft. lbs.) torque.
(3) Using the transmission jack, lower the trans-
mission and support cushion onto the crossmember
(Fig. 50).
(4) Install the support cushion bolts and tighten to
47 N´m (35 ft. lbs.) torque.
(5) Remove the transmission jack.
(6) Lower the vehicle.
Fig. 147 Engine Rear Support Cushion Assembly
BR/BEENGINE 5.9L DIESEL 9 - 291

²Milky discoloration indicates coolant dilution.
(4) Clean the area around the oil filter head.
Remove the filter (Refer to 9 - ENGINE/LUBRICA-
TION/OIL FILTER - REMOVAL).
(5) Install new oil filter (Refer to 9 - ENGINE/LU-
BRICATION/OIL FILTER - INSTALLATION).
(6) Clean the drain plug and the sealing surface of
the pan. Check the condition of the threads and seal-
ing surface on the oil pan and drain plug.
(7) Install the drain plug. Tighten the plug to 60
N´m (44 ft. lbs.) torque.
(8) Use only High-Quality Multi-Viscosity lubricat-
ing oil in the Cummins Turbo Diesel engine. Choose
the correct oil for the operating conditions (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
(9) Fill the engine with the correct grade of new oil
(Refer to LUBRICATION & MAINTENANCE/FLUID
CAPACITIES - SPECIFICATIONS).
(10) Start the engine and operate it at idle for sev-
eral minutes. Check for leaks at the filter and drain
plug.
(11) Stop engine. Wait several minutes to allow the
oil to drain back to the pan and check the level
again.
USED ENGINE OIL DISPOSAL Care should be
exercised when disposing of used engine oil after
it has been drained from a vehicle's engine.
OIL COOLER & LINES
CLEANING AND INSPECTION
Clean the sealing surfaces.
Apply 483 kPa (70 psi) air pressure to the element
to check for leaks. If the element leaks, replace the
element.
OIL FILTER
REMOVAL
(1) Clean the area around the oil filter head.
Remove the filter using a 90-95 mm filter wrench.
(2) Clean the gasket surface of the filter head. The
filter canister O-Ring seal can stick on the filter
head. Make sure it is removed.
INSTALLATION
(1) Fill the oil filter element with clean oil before
installation. Use the same type oil that will be used
in the engine.
(2) Apply a light film of lubricating oil to the seal-
ing surface before installing the filter.CAUTION: Mechanical over-tightening may distort
the threads or damage the filter element seal.
(3) Install the filter until it contacts the sealing
surface of the oil filter adapter. Tighten filter an
additional ó turn.
OIL PAN
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Remove transmission and transfer case (if
equipped).
(4) Remove flywheel.
(5) Disconnect starter cables from starter motor.
(6) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
and transmission adapter plate assembly.
WARNING: HOT OIL CAN CAUSE PERSONAL
INJURY.
(7) Drain the engine oil (Refer to 9 - ENGINE/LU-
BRICATION/OIL - STANDARD PROCEDURE).
(8) Install the oil pan drain plug with a new seal-
ing washer and tighten to 60 N´m (44 ft. lbs.) torque.
(9) Remove oil pan bolts, break the pan to block
seal, and lower pan slightly and remove oil suction
tube fasteners.
(10) Remove oil pan and suction tube (Fig. 151).
Fig. 151 Oil Pan, Suction Tube and Gasket
1 - GASKET
2 - SUCTION TUBE
3 - OIL PAN
9 - 296 ENGINE 5.9L DIESELBR/BE
OIL (Continued)

EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION............................1
DIAGNOSIS AND TESTING..................4
GAS ENGINE...........................4
DIESEL ENGINE........................4
SPECIFICATIONS.........................5
CATALYTIC CONVERTER - 3.9L/5.2L/5.9L
DESCRIPTION............................5
OPERATION.............................5
REMOVAL...............................5
INSPECTION.............................5
INSTALLATION............................5
CATALYTIC CONVERTER - 5.9L HEAVY
DUTY/8.0L
DESCRIPTION............................6
OPERATION.............................6
REMOVAL...............................6
INSPECTION.............................7
INSTALLATION............................7
EXHAUST PIPE - 3.9L/5.2L/5.9L
REMOVAL...............................7
INSPECTION.............................7
INSTALLATION............................7
EXHAUST PIPE - 5.9L HEAVY DUTY/8.0L
REMOVAL...............................8
INSPECTION.............................9
INSTALLATION............................9
EXHAUST PIPE - 5.9L DIESEL
REMOVAL...............................9
INSPECTION.............................9
INSTALLATION...........................10
HEAT SHIELDS
DESCRIPTION...........................10
REMOVAL..............................10
INSTALLATION...........................10MUFFLER - 3.9L/5.2L/5.9L/8.0L
REMOVAL..............................10
INSTALLATION...........................11
MUFFLER - 5.9L DIESEL
REMOVAL..............................11
INSTALLATION...........................11
TAILPIPE - 3.9L/5.2L/5.9L
REMOVAL..............................11
INSPECTION............................11
INSTALLATION...........................12
TAILPIPE - 5.9L HEAVY DUTY/8.0L
REMOVAL..............................12
INSPECTION............................12
INSTALLATION...........................12
TAILPIPE - 5.9L DIESEL
REMOVAL..............................12
INSPECTION............................12
INSTALLATION...........................12
RESONATOR
REMOVAL..............................13
INSTALLATION...........................13
TURBOCHARGER
DESCRIPTION...........................13
OPERATION.............................13
REMOVAL..............................15
CLEANING..............................16
INSPECTION............................16
INSTALLATION...........................16
CHARGE AIR COOLER AND PLUMBING
DESCRIPTION...........................17
OPERATION.............................17
REMOVAL..............................17
CLEANING..............................18
INSPECTION............................18
INSTALLATION...........................18
EXHAUST SYSTEM
DESCRIPTIONÐ3.9L/5.2L/5.9/8.0L
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-tem floor pan exhaust heat shields. Light overspray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.
BR/BEEXHAUST SYSTEM 11 - 1

DESCRIPTIONÐ5.9L DIESEL
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem floor pan exhaust heat shields. Light overspray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.
The diesel engine exhaust system consists of an
engine exhaust manifold, turbocharger, exhaust pipe,
resonator, extension pipe (if needed), muffler and
exhaust tailpipe.
The exhaust system must be properly aligned to
prevent stress, leakage and body contact. The
exhaust components should be kept a minimum of
25.4 mm (1.0 in.) away from the body and frame. If
the system contacts any body panel, it may amplify
objectionable noises from the engine or body.
Fig. 2 Catalytic Converter with Pipes and Mini
Catalytic Converters
1 - BOLT
2 - RETAINER
3 - EXHAUST MANIFOLD
4 - NUT
5 - MINI CATALYTIC CONVERTER
6 - CATALYTIC CONVERTER WITH PIPES
BR/BEEXHAUST SYSTEM 11 - 3
EXHAUST SYSTEM (Continued)

SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Adjusting StrapÐBolt 23 Ð 200
Air Heater Power SupplyÐ
Nuts14 Ð 124
Air Inlet HousingÐBolts 24 18 Ð
Cab Heater Supply/Return
LineÐNuts24 18 Ð
Exhaust ClampÐNuts 48 35 Ð
Exhaust Manifold to Cylinder
HeadÐBolts
(Diesel Engine) 43 32 Ð
Exhaust Manifold to Cylinder
HeadÐBolts
(3.9L/5.2L/5.9L) 31 23 Ð
Exhaust Manifold to Cylinder
HeadÐBolts
(8.0L) 22 Ð 195
Exhaust Pipe to ManifoldÐ
Bolts31 23 Ð
Generator MountingÐBolts 41 30 Ð
Charge Air Cooler
MountingÐBolts2Ð17
Charge Air Cooler DuctÐ
Nuts8Ð72
Heat ShieldÐNuts and Bolts 11 Ð 100
Turbocharger MountingÐ
Nuts32 24 Ð
Turbocharger Oil Drain
TubeÐBolts24 18 Ð
Turbocharger Oil Supply
LineÐFitting15 Ð 133
Turbocharger V-Band
ClampÐNut9Ð75
CATALYTIC CONVERTER -
3.9L/5.2L/5.9L
DESCRIPTION
The stainless steel catalytic converter is located
under the vehicle, integral to the exhaust pipe(s).
OPERATION
The catalytic converter captures and burns any
unburned fuel mixture exiting the combustion cham-
bers during the exhaust stroke of the engine. This
process aids in reducing emissions output.
REMOVAL
(1) Raise and support vehicle.
(2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove clamps and nuts (Fig. 3) (Fig. 4).
(4) Remove the catalytic converter.
INSPECTION
Look at the stainless steel body of the converter,
inspect for bulging or other distortion that could be a
result of overheating. If the converter has a heat
shield attached make sure it is not bent or loose.
If you suspect internal damage to the catalyst, tap-
ping the bottom of the catalyst with a rubber mallet
may indicate a damaged core.
INSTALLATION
(1) Assemble converter and clamps loosely in
place.
Fig. 3 Catalytic Converter and Exhaust Pipe 3.9L,
5.2L and 5.9L Light Duty ( Federal )
1 - BOLT
2 - EXHAUST PIPE W/CONVERTER
3 - NUT
4 - RETAINER
BR/BEEXHAUST SYSTEM 11 - 5