2001 DODGE RAM engine

INSTALLATION
(1) Clean valves thoroughly. Discard burned,
warped and cracked valves.
(2) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(3) Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 inch), replace the valve.
(4) Coat valve stems with lubrication oil and insert
them in cylinder head.
(5) If valves or seats are reground, check valve
stem height. If valve is too long, replace cylinder
head.
(6) Install new seals on all valve guides. Install
valve springs and valve retainers.
(7) Compress valve springs with Valve Spring
Compressor Tool MD-998772A and adapter 6716A,
install locks and release tool. If valves and/or seats
are ground, measure the installed height of springs.
Make sure the measurement is taken from bottom of
spring seat in cylinder head to the bottom surface of
spring retainer. If spacers are installed, measure
from the top of spacer. If height is greater than 42.86
mm (1-11/16 inches), install a 1.587 mm (1/16 inch)
spacer in head counterbore. This should bring spring
height back to normal 41.27 to 42.86 mm (1-5/8 to
1-11/16 inch).
(8) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
ENGINE BLOCK
CLEANING
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leakage.
INSPECTION
Examine block for cracks or fractures.
The cylinder walls should be checked for out-of-
round and taper. Refer to Honing Cylinder Bores in
the Service Procedures portion of this Section.
Inspect the oil line plug, the oil line plug is located
in the vertical passage at the rear of the block
between the oil-to-filter and oil-from-filter passages
(Fig. 17). Improper installation or missing plug could
cause erratic, low, or no oil pressure.
The oil plug must come out the bottom. Use flat
dowel, down the oil pressure sending unit hole from
the top, to remove oil plug.
(1) Remove oil pressure sending unit from back of
block.
(2) Insert a 3.175 mm (1/8 in.) finish wire, or
equivalent, into passage.
(3) Plug should be 190.0 to 195.2 mm (7-1/2 to
7-11/16 in.) from machined surface of block (Fig. 17).
If plug is too high, use a suitable flat dowel to posi-
tion properly.
(4)
If plug is too low, remove oil pan and No. 4 main
bearing cap. Use suitable flat dowel to position properly.
Coat outside diameter of plug with MopartStud and
Fig. 16 Measuring Valve Guide Wear
1 - VALVE
2 - SPECIAL TOOL C-3339
Fig. 17 Oil Line Plug
1 - RIGHT OIL GALLERY
2 - CYLINDER BLOCK
3 - OIL FROM FILTER TO SYSTEM
4 - OIL TO FILTER
5 - FROM OIL PUMP
6 - CRANKSHAFT
7 - PLUG
9 - 28 ENGINE 3.9LBR/BE
INTAKE/EXHAUST VALVES & SEATS (Continued)

Bearing Mount Adhesive. Plug should be 54.0 to 57.7
mm (2-1/8 to 2-5/16 in.) from bottom of the block.
CAMSHAFT & BEARINGS (IN
BLOCK)
REMOVALÐCAMSHAFT BEARINGS
(1) With engine completely disassembled, drive out
rear cam bearing core hole plug.
(2) Install proper size adapters and horseshoe
washers (part of Camshaft Bearing Remover/Installer
Tool C-3132-A) at back of each bearing shell. Drive
out bearing shells (Fig. 18).
REMOVALÐCAMSHAFT
(1) Disconnect battery negative cable.
(2) Remove radiator. (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(3) Remove intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL).
(4) Remove distributor assembly. Refer to Ignition
Systems for the correct procedure.
(5) Remove cylinder head covers (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(6) Remove rocker arms.
(7) Remove push rods and tappets (Refer to 9 -
ENGINE/ENGINE BLOCK/HYDRAULIC LIFTERS
(CAM IN BLOCK) - REMOVAL). Identify each part
so it can be installed in the original locations.
(8) Remove timing chain cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(9) Align timing marks (Fig. 19) and remove tim-
ing chain and sprockets.
(10) Remove the three tensioner to block mounting
bolts and remove tensioner.(11) Install a long bolt into front of camshaft to aid
in removal of the camshaft. Remove camshaft, being
careful not to damage cam bearings with the cam
lobes.
INSTALLATIONÐCAMSHAFT BEARINGS
(1) Install new camshaft bearings with Camshaft
Bearing Remover/Installer Tool C-3132-A by sliding
the new camshaft bearing shell over proper adapter.
(2) Position rear bearing in the tool. Install horse-
shoe lock and, by reversing removal procedure, care-
fully drive bearing shell into place.
(3) Install remaining bearings in the same man-
ner. Bearings must be carefully aligned to bring oil
holes into full register with oil passages from the
main bearing. If the camshaft bearing shell oil holes
are not in exact alignment, remove and install them
correctly. Install a new core hole plug at the rear of
camshaft.Be sure this plug does not leak.
INSTALLATIONÐCAMSHAFT
(1) Lubricate camshaft lobes and camshaft bearing
journals and insert the camshaft to within 51 mm (2
inches) of its final position in cylinder block.
(2) Install Camshaft Holding Tool C-3509 with
tongue back of distributor drive gear (Fig. 20).
(3) Hold tool in position with a distributor lock-
plate bolt. This tool will restrict camshaft from being
pushed in too far and prevent knocking out the welch
plug in rear of cylinder block.Tool should remain
Fig. 18 Camshaft Bearings Removal and Installation
with Tool C-3132-A
1 - SPECIAL TOOL C-3132A
Fig. 19 Alignment of Timing Marks
1 - TIMING MARKS
BR/BEENGINE 3.9L 9 - 29
ENGINE BLOCK (Continued)

installed until the camshaft and crankshaft
sprockets and timing chain have been installed.
(4) Install timing chain tensioner. Torque bolts to
24 N´m (210 in. lbs.) torque.
(5) Compress tensioner shoe (Fig. 21) and install a
suitable sized pin to retain shoe for chain installa-
tion.
(6) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on an exact
imaginary center line through both camshaft and
crankshaft bores.(7) Place timing chain around both sprockets.
Fig. 20 Camshaft Holding Tool C-3509 (Installed
Position)
1 - SPECIAL TOOL C-3509
2 - DRIVE GEAR
3 - DISTRIBUTOR LOCK BOLT
Fig. 21 Compressing Tensioner Shoe For Timing
Chain Installation
1 - SCREWDRIVER
2 - INSERT PIN HERE
Fig. 22 Alignment of Timing Marks
1 - TIMING MARKS
Fig. 23 Checking Camshaft End Play
1 - SCREWDRIVER
2 - DIAL INDICATOR
3 - CAM SPROCKET
9 - 30 ENGINE 3.9LBR/BE
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

(8) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam-
shaft sprocket.
(9) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(10) Slide both sprockets evenly over their respec-
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 22).
(11) Install the camshaft bolt/cup washer. Tighten
bolt to 68 N´m (50 ft. lbs.) torque.
(12) Measure camshaft end play (Fig. 23). (Refer to
9 - ENGINE - SPECIFICATIONS) for proper clear-
ance. If not within limits, install a new timing chain
tensioner.
(13) Each tappet reused must be installed in the
same position at which it was removed.When cam-
shaft is replaced, all of the tappets must be
replaced.Install hydraulic tappets (Refer to 9 -
ENGINE/ENGINE BLOCK/HYDRAULIC LIFTERS
(CAM IN BLOCK) - INSTALLATION).
(14) Install timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(15) Install intake manifold (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSTALLA-
TION).
(16) Install distributor.
(17) Install cylinder head covers (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(18) Install radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - INSTALLATION).
(19) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(20) Connect battery negative cable.
(21) Start engine and check for leaks.
CONNECTING ROD BEARINGS
STANDARD PROCEDURE-CONNECTING ROD
BEARING FITTING
Fit all rods on a bank until completed. DO NOT
alternate from one bank to another, because connect-
ing rods and pistons are not interchangeable from
one bank to another.
The bearing caps are not interchangeable and
should be marked at removal to ensure correct
assembly.
Each bearing cap has a small V-groove across the
parting face. When installing the lower bearing shell,
be certain that the V-groove in the shell is in line
with the V-groove in the cap. This provides lubrica-
tion of the cylinder wall in the opposite bank.The bearing shells must be installed so that the
tangs are in the machined grooves in the rods and
caps.
Limits of taper or out-of-round on any crankshaft
journals should be held to 0.025 mm (0.001 in.).
Bearings are available in 0.025 mm (0.001 in.), 0.051
mm (0.002 in.), 0.076 mm (0.003 in.), 0.254 mm
(0.010 in.) and 0.305 mm (0.012 in.) undersize.
Install the bearings in pairs. DO NOT use a new
bearing half with an old bearing half. DO NOT
file the rods or bearing caps.
CRANKSHAFT
DESCRIPTION
The crankshaft (Fig. 24) is of a forged steel splayed
type design, with four main bearing journals.The
crankshaft is located at the bottom of the engine
block and is held in place with four main bearing
caps.
OPERATION
The crankshaft transfers force generated by com-
bustion within the cylinder bores to the flywheel or
flexplate.
REMOVAL
(1) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(2) Remove the oil pump (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - REMOVAL).
(3) Identify bearing caps before removal. Remove
bearing caps and bearings one at a time.
(4) Lift the crankshaft out of the block.
Fig. 24 CrankshaftÐ3.9L Engine
BR/BEENGINE 3.9L 9 - 31
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

(5) Remove and discard the crankshaft rear oil
seals.
(6) Remove and discard the front crankshaft oil
seal.
INSTALLATION
(1) Lightly oil the new upper seal lips with engine
oil.
(2) Install the new upper rear bearing oil seal with
the white paint facing towards the rear of the engine.
(3) Position the crankshaft into the cylinder block.
(4) Lightly oil the new lower seal lips with engine
oil.
(5) Install the new lower rear bearing oil seal into
the bearing cap with the white paint facing towards
the rear of the engine.
(6) Apply 5 mm (0.20 in.) drop of Loctite 518, or
equivalent, on each side of the rear main bearing cap
(Fig. 25). DO NOT over-apply sealant or allow the
sealant to contact the rubber seal. Assemble bearing
cap to cylinder block immediately after sealant appli-
cation.
(7) To align the bearing cap, use cap slot, align-
ment dowel, and cap bolts. DO NOT remove excess
material after assembly. DO NOT strike rear cap
more than two times for proper engagement.
(8) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately
tighten to 115 N´m (85 ft. lbs.) torque.
(9) Install oil pump (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PUMP - INSTALLATION).
(10) Apply MopartSilicone Rubber Adhesive Seal-
ant, or equivalent, at bearing cap-to-block joint to
provide cap-to-block and oil pan sealing (Fig. 26).Apply enough sealant so that a small amount is
squeezed out. Withdraw nozzle and wipe excess seal-
ant off the oil pan seal groove.
(11) Install new front crankshaft oil seal (Refer to
9 - ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - FRONT - INSTALLATION).
(12) Immediately install the oil pan (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
(13) Install new rear oil seal (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - INSTALLATION).
CRANKSHAFT MAIN
BEARINGS
DESCRIPTION
Main bearings (Fig. 27) are located in the cylinder
block. One half of the main bearing is located in the
crankshaft main bore the other half of the matching
bearing is located in the main bearing cap. there are
four main bearings. Number two main bearing is
flanged, this flange controls crankshaft thrust.
OPERATION
The main bearings encircle the crankshaft main
bearing journals, this aligns the crankshaft to the
centerline of the engine and allows the crankshaft to
turn without wobbling or shaking therefore eliminat-
ing vibration. The main bearings are available in
standard and undersizes.
Fig. 25 Sealant Application to Bearing Cap
1 - MOPAR SILICONE RUBBER ADHESIVE SEALANT SLOTS
2 - LOCTITE 515 (OR EQUIVALENT)
3 - CAP ALIGNMENT SLOT
4 - REAR MAIN BEARING CAP
Fig. 26 Apply Sealant to Bearing Cap-to-Block Joint
1 - MOPARTGEN II SILICONE RUBBER ADHESIVE SEALANT
NOZZLE TIP
2 - SEALANT APPLIED
3 - CYLINDER BLOCK
4 - REAR MAIN BEARING CAP
9 - 32 ENGINE 3.9LBR/BE
CRANKSHAFT (Continued)

STANDARD PROCEDUREÐMAIN BEARING
FITTING
Bearing caps are NOT interchangeable and should
be marked at removal to ensure correct assembly.
Upper and lower bearing halves are NOT inter-
changeable. Lower main bearing halves of No. 1 and
3 are interchangeable.
Upper and lower No. 2 bearing halves are flanged
to carry the crankshaft thrust loads. They are NOT
interchangeable with any other bearing halves in the
engine (Fig. 28). Bearing shells are available in stan-
dard and the following undersizes: 0.25 mm (0.001
in.), 0.051 mm (0.002 in.), 0.076 mm (0.003 in.), 0.254
mm (0.010 in.) and 0.305 mm (0.012 in.). Never
install an undersize bearing that will reduce clear-
ance below specifications.
CRANKSHAFT IDENTIFICATION LOCATION
CHART
ITEM MEASUREMENT IDENTIFICATION
ROD U/S 0.025 mm R1-R2-R3 ect.
(0.001 in.) indicates rod
journal
No. 1, 2 and 3.
MAIN U/S 0.025 mm M1-M2-M3 or M4
(0.001 in.) indicates main
journal
No. 1, 2, 3, and 4.
REMOVAL
(1) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(2) Remove the oil pump (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - REMOVAL).
(3) Identify bearing caps before removal. Remove
bearing caps one at a time.
(4) Remove upper half of bearing by inserting
Crankshaft Main Bearing Remover/Installer Tool
C-3059 into the oil hole of crankshaft (Fig. 29).
(5) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
Fig. 27 Main Bearing Orientation
Fig. 28 Main Bearing IdentificationFig. 29 Upper Main Bearing Removal and
Installation with Tool C-3059
1 - SPECIAL TOOL C-3059
2 - BEARING
3 - SPECIAL TOOL C-3059
4 - BEARING
BR/BEENGINE 3.9L 9 - 33
CRANKSHAFT MAIN BEARINGS (Continued)

INSTALLATION
Only one main bearing should be selectively fitted
while all other main bearing caps are properly tight-
ened. All bearing capbolts removed during service
procedures are to be cleaned and oiled before instal-
lation. DO NOT use a new bearing half with an old
bearing half.
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
(1) Start bearing in place, and insert Crankshaft
Main Bearing Remover/Installer Tool C-3059 into oil
hole of crankshaft (Fig. 29).
(2) Slowly rotate crankshaft counterclockwise slid-
ing the bearing into position. Remove Tool C-3059.
(3) Install the bearing caps. Clean and oil the
bolts. Tighten the capbolts to 115 N´m (85 ft. lbs.)
torque.
(4) Install the oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(5) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
CRANKSHAFT OIL SEAL -
FRONT
DESCRIPTION
The crankshaft rear seal is a two piece viton seal.
The crankshaft front seal is a one piece viton seal
with a steel housing. The front seal is located in the
engine front cover. One part of the two piece rear
seal is located in a slot in the number four (4) crank-
shaft main bore, the second part of the two piece seal
is located in the number four (4) main bearing cap.
OPERATION
The crankshaft seals prevent oil from leaking from
around the crankshaft, either from the rear of the
engine or from the engine front cover.
REMOVAL
The oil seal can be replaced without removing the
timing chain cover, provided that the cover is not
misaligned.
(1) Disconnect the negative cable from the battery.
(2) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(3) If front seal is suspected of leaking, check front
oil seal alignment to crankshaft. The seal installa-
tion/alignment Tool 6635, should fit with minimum
interference. If tool does not fit, the cover must be
removed and installed properly.
(4) Place a suitable tool behind the lips of the oil
seal to pry the oil seal outward. Be careful not to
damage the crankshaft seal bore of cover.
INSTALLATION
(1) Place the smaller diameter of the oil seal over
Front Oil Seal Installation Tool 6635 (Fig. 30). Seat
the oil seal in the groove of the tool.
(2) Position the seal and tool onto the crankshaft
(Fig. 31).
(3) Using the vibration damper bolt, tighten the
bolt to draw the seal into position on the crankshaft
(Fig. 32).
(4) Remove the vibration damper bolt and seal
installation tool.
(5) Inspect the seal flange on the vibration
damper.
(6) Install the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(7) Connect the negative cable to the battery.
CRANKSHAFT OIL SEAL -
REAR
DESCRIPTION
The crankshaft rear seal is a two piece viton seal.
The crankshaft front seal is a one piece viton seal
with a steel housing. The front seal is located in the
engine front cover. One part of the two piece rear
seal is located in a slot in the number four (4) crank-
shaft main bore, the second part of the two piece seal
is located in the number four (4) main bearing cap.
OPERATION
The crankshaft seals prevent oil from leaking from
around the crankshaft, either from the rear of the
engine or from the engine front cover.
Fig. 30 Placing Oil Seal on Installation Tool 6635
1 - CRANKSHAFT FRONT OIL SEAL
2 - INSTALL THIS END INTO SPECIAL TOOL 6635
9 - 34 ENGINE 3.9LBR/BE
CRANKSHAFT MAIN BEARINGS (Continued)

REMOVAL
The service seal is a two piece, Viton seal. The
upper seal half can be installed with crankshaftremoved from engine or with crankshaft installed.
When a new upper seal is installed, install a new
lower seal. The lower seal half can be installed only
with the rear main bearing cap removed.
UPPER SEAL ÐCRANKSHAFT REMOVED
(1) Remove the crankshaft (Refer to 9 - ENGINE/
ENGINE BLOCK/CRANKSHAFT - REMOVAL). Dis-
card the old upper seal.
UPPER SEALÐCRANKSHAFT INSTALLED
(1) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(2) Remove the oil pump (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - REMOVAL).
(3) Remove the rear main bearing cap. Remove
and discard the old lower oil seal.
(4) Carefully remove and discard the old upper oil
seal.
LOWER SEAL
(1) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(2) Remove the oil pump (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - REMOVAL).
(3) Remove the rear main bearing cap and discard
the old lower seal.
INSTALLATION
The service seal is a two piece, Viton seal. The
upper seal half can be installed with crankshaft
removed from engine or with crankshaft installed.
When a new upper seal is installed, install a new
lower seal. The lower seal half can be installed only
with the rear main bearing cap removed.
UPPER SEAL ÐCRANKSHAFT REMOVED
(1) Clean the cylinder block rear cap mating sur-
face. Be sure the seal groove is free of debris. Check
for burrs at the oil hole on the cylinder block mating
surface to rear cap.
(2) Lightly oil the new upper seal lips with engine
oil.
(3) Install the new upper rear bearing oil seal with
the white paint facing toward the rear of the engine.
(4) Position the crankshaft into the cylinder block.
(5) Lightly oil the new lower seal lips with engine
oil.
(6) Install the new lower rear bearing oil seal into
the bearing cap with the white paint facing towards
the rear of the engine.
(7) Apply 5 mm (0.20 in.) drop of MopartGasket
Maker, or equivalent, on each side of the rear main
bearing cap (Fig. 33). DO NOT over-apply sealant or
allow the sealant to contact the rubber seal. Assem-
Fig. 31 Position Tool and Seal onto Crankshaft
1 - SPECIAL TOOL 6635
2 - OIL SEAL
3 - TIMING CHAIN COVER
Fig. 32 Installing Oil Seal
1 - SPECIAL TOOL 6635
2 - TIMING CHAIN COVER
BR/BEENGINE 3.9L 9 - 35
CRANKSHAFT OIL SEAL - REAR (Continued)