2001 DODGE RAM engine

(3) Install the relief valve and spring. Insert the
cotter pin.
(4) Tap on a new retainer cap.
(5) Prime oil pump before installation by filling
rotor cavity with engine oil.
INSTALLATION
(1) Install oil pump. During installation, slowly
rotate pump body to ensure driveshaft-to-pump rotor
shaft engagement.(2) Hold the oil pump base flush against mating
surface on No. 4 main bearing cap. Finger-tighten
pump attaching bolts. Tighten attaching bolts to 41
N´m (30 ft. lbs.) torque.
(3) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
INTAKE MANIFOLD
DESCRIPTION
The aluminum intake manifold (Fig. 66) is a single
plane design with equal length runners. This mani-
fold uses a separate plenum pan and gasket, there-
fore the plenum gasket is servicable. It also uses
separate flange gaskets and front and rear cross-over
gaskets. Extreme care must be used when sealing
the gaskets to ensure that excess sealant does not
enter the intake runners causing a restriction.
OPERATION
The intake manifold, meters and delivers air to the
combustion chambers allowing the fuel delivered by
the fuel injectors to ignite, thus producing power.
Fig. 64 Measuring Clearance Over Rotors
1 - STRAIGHT EDGE
2 - FEELER GAUGE
Fig. 65 Proper Installation of Retainer Cap
1 - RETAINER CAP
2 - CHAMFER
3 - COTTER KEY
Fig. 66 Intake Manifold with Tightening SequenceÐ
3.9L Engine
9 - 52 ENGINE 3.9LBR/BE
OIL PUMP (Continued)

DIAGNOSIS AND TESTINGÐINTAKE
MANIFOLD LEAKAGE
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS, OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water at the suspected
leak area.
(3) If a change in RPMs, the area of the suspected
leak has been found.
(4) Repair as required.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(3) Remove the A/C compressor (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - REMOVAL).
(4) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(5) Remove the accessory drive bracket.
(6) Remove the air cleaner.
(7) Perform the Fuel System Pressure release pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY - STANDARD PROCEDURE). Disconnect the
fuel lines (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(8) Disconnect the accelerator linkage (Refer to 14
- FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - REMOVAL) and if so equipped,
the speed control and transmission kickdown cables.
(9) Remove the return spring.
(10) Remove the distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect the heat indicator sending unit
wire.
(13) Disconnect the heater hoses and bypass hose.
(14) Remove the closed crankcase ventilation and
evaporation control systems.
(15) Remove intake manifold bolts.
(16) Lift the intake manifold and throttle body out
of the engine compartment as an assembly.
(17) Remove and discard the flange side gaskets
and the front and rear cross-over gaskets.(18) Remove the throttle body (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/THROTTLE BODY -
REMOVAL).
(19) If required, remove the plenum pan and gas-
ket. Discard gasket.
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
The plenum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.
INSTALLATION
(1) If the plenum pan was removed, position a new
gasket and install the plenum pan (Fig. 67). Tighten
bolts in the following sequence:
²Step 1. Tighten bolts to 5.4 N´m (48 in. lbs.)
²Step 2. Tighten bolts to 9.5 N´m (84 in. lbs.)
²Step 3. Check bolts to 9.5 N´m (84 in. lbs.)
(2) Install the flange gaskets. Ensure that the ver-
tical port alignment tab is resting on the deck face of
the block. Also the horizontal alignment tabs must be
in position with the mating cylinder head gasket tabs
(Fig. 69). The words MANIFOLD SIDE should be vis-
ible on the center of each flange gasket.
Fig. 67 Plenum Pan Bolt Tightening Sequence
BR/BEENGINE 3.9L 9 - 53
INTAKE MANIFOLD (Continued)

(3) Apply MopartGEN II Silicone Rubber Adhe-
sive Sealant, or equivalent, to the four corner joints.
An excessive amount of sealant is not required to
ensure a leak proof seal. However, an excessive
amount of sealant may reduce the effectiveness of
the flange gasket and crossÐover gaskets (Fig. 68).
The sealant should be approximately 5 mm (0.2 in)
in diameter.
(4) Install the front and rear cross-over gaskets.
(5) Using a new gasket, install the throttle body
onto the intake manifold (Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/THROTTLE BODY -
INSTALLATION).
(6) Carefully lower intake manifold into position
on the cylinder block and cylinder heads. After intake
manifold is in place, inspect to make sure seals are
in place.
(7) Install the intake manifold bolts and tighten as
follows (Fig. 70):
²Step 1. Tighten bolts 1 and 2 to 8 N´m (72 in.
lbs.) Tighten in alternating steps 1.4 N´m (12 in. lbs.)
at a time
²Step 2. Tighten bolts 3 through 12 to 8 N´m (72
in. lbs.)
²Step 3. Check all bolts are torqued to 8 N´m (72
in. lbs.)
²Step 4. Tighten all bolts in sequence to 16 N´m
(12 ft. lbs.)
²Step 5. Check all bolts are torqued to 16 N´m
(12 ft. lbs.)
Fig. 68 Cross-Over Gaskets
1 - FRONT CROSS-OVER GASKET
2 - REAR CROSS-OVER GASKET
Fig. 69 Intake Manifold Flange Gasket Alignment
1 - FLANGE GASKET
2 - ALIGNMENT TABS
3 - CYLINDER HEAD GASKET
Fig. 70 Intake Manifold Bolt Tightening Sequence
9 - 54 ENGINE 3.9LBR/BE
INTAKE MANIFOLD (Continued)

(8) Install closed crankcase ventilation and evapo-
ration control systems.
(9) Connect the coil wires.
(10) Connect the heat indicator sending unit wire.
(11) Connect the heater hoses and bypass hose.
(12) Install distributor cap and wires.
(13) Hook up the return spring.
(14) Connect the accelerator linkage (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - INSTALLATION) and if so
equipped, the speed control and transmission kick-
down cables.
(15) Install the fuel lines (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE).
(16) Install the accessory drive bracket and A/C
Compressor (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/A/C COMPRESSOR -
INSTALLATION).
(17) Install the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - INSTALLATION)
and drive belt (Refer to 7 - COOLING/ACCESSORY
DRIVE/DRIVE BELTS - INSTALLATION).
(18) Install the air cleaner.
(19) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(20) Connect the negative cable to the battery.
EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifolds (Fig. 71) are constructed of
cast iron and are LOG type with balanced flow. One
exhaust manifold is attached to each cylinder head.
OPERATION
The exhaust manifolds collect the engine exhaust
exiting the combustion chambers, then channels the
exhaust gases to the exhaust pipes attached to the
manifolds.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Raise and support the vehicle.
(3) Disconnect the exhaust pipe from the exhaust
manifold (Refer to 11 - EXHAUST SYSTEM/EX-
HAUST PIPE - REMOVAL).
(4) Lower the vehicle.
(5) Remove the exhaust heat shields.
(6) Remove bolts, nuts and washers attaching
manifold to cylinder head.
(7) Remove manifold from the cylinder head.
CLEANING
Clean mating surfaces on cylinder head and mani-
fold. Wash with solvent and blow dry with com-
pressed air.
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straight edge. Gasket surfaces must be flat
within 0.2 mm per 300 mm (0.008 inch per foot).
INSTALLATION
CAUTION: If the studs came out with the nuts when
removing the engine exhaust manifold, install new
studs. Apply sealer on the coarse thread ends.
Water leaks may develop at the studs if this precau-
tion is not taken.
(1) Position the engine exhaust manifolds on the
two studs located on the cylinder head. Install coni-
cal washers and nuts on these studs (Fig. 72).
(2) Install two bolts and conical washers at the
inner ends of the engine exhaust manifold outboard
arms. Install two bolts WITHOUT washers on the
center arm of engine exhaust manifold (Fig. 72).
Starting at the center arm and working outward,
tighten the bolts and nuts to 34 N´m (25 ft. lbs.)
torque.
(3) Install the exhaust heat shields.
(4) Raise and support the vehicle.
Fig. 71 Exhaust ManifoldsÐ3.9L Engine
1 - EXHAUST MANIFOLD (RIGHT)
2 - EXHAUST MANIFOLD (LEFT)
3 - BOLTS & WASHERS
4 - NUTS & WASHERS
BR/BEENGINE 3.9L 9 - 55
INTAKE MANIFOLD (Continued)

(5) Assemble exhaust pipe to manifold and secure
with bolts, nuts and retainers. Tighten the bolts and
nuts to 34 N´m (25 ft. lbs.) torque.
(6) Lower the vehicle.
(7) Connect the negative cable to the battery.
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(1) Disconnect the battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - REMOV-
AL).
(4) Remove water pump (Refer to 7 - COOLING/
ENGINE/WATER PUMP - REMOVAL).
(5) Remove power steering pump (Refer to 19 -
STEERING/PUMP - REMOVAL).
(6) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(7) Loosen oil pan bolts and remove the front bolt
at each side.
(8) Remove the cover bolts.
(9) Remove chain case cover and gasket using
extreme caution to avoid damaging oil pan gasket.
(10) From the inside of the cover tap the front
crankshaft oil seal outward. Be careful not to damage
the timing cover sealing surface.
INSTALLATION
(1) Be sure mating surfaces of chain case cover
and cylinder block are clean and free from burrs.
(2) Using a new cover gasket, carefully install
chain case cover to avoid damaging oil pan gasket.
Use a small amount of MopartGEN II Silicone Rub-
ber Adhesive Sealant, or equivalent, at the joint
between timing chain cover gasket and the oil pan
gasket. Finger tighten the timing chain cover bolts at
this time.
CAUTION: If chain cover is replaced for any reason,
be sure the oil hole (passenger side of cover) is
plugged.
NOTE: Special Tool 6635 must be used to align
cover and seal with crankshaft.
(3) Position the special tool 6635 onto the crank-
shaft (Fig. 73).
(4) Tighten chain case cover bolts to 41 N´m (30 ft.
lbs.) torque. Tighten oil pan bolts to 24 N´m (215 in.
lbs.) torque.
(5) Remove special tool 6635.
(6) Inspect the seal flange on the vibration
damper.
(7) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
Fig. 72 Engine Exhaust Manifold InstallationÐ3.9L
Engine
1 - EXHAUST MANIFOLD (RIGHT)
2 - EXHAUST MANIFOLD (LEFT)
3 - BOLTS & WASHERS
4 - NUTS & WASHERS
Fig. 73 Position Special Tool 6635 onto Crankshaft
1 - SPECIAL TOOL 6635
2 - OIL SEAL
3 - TIMING CHAIN COVER
9 - 56 ENGINE 3.9LBR/BE
EXHAUST MANIFOLD (Continued)

(8) Install water pump (Refer to 7 - COOLING/EN-
GINE/WATER PUMP - INSTALLATION).
(9) Install power steering pump (Refer to 19 -
STEERING/PUMP - INSTALLATION).
(10) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(11) Install the cooling system fan (Refer to 7 -
COOLING/ENGINE/FAN DRIVE VISCOUS
CLUTCH - INSTALLATION).
(12) Position the fan shroud and install the bolts.
Tighten the bolts to 11 N´m (95 in. lbs.) torque.
(13) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(14) Connect the negative cable to the battery.
TIMING BELT/CHAIN
TENSIONER
DESCRIPTION
The timing chain tensioner is a stamped steel con-
stant tension mechanical design. It is mounted to the
front of the engine, behind the timing chain drive.
OPERATION
The timing chain tension is maintained by routing
the timing chain through the tensioner assembly. A
nylon covered spring steel arm presses on the timing
chain maintaining the correct chain tension.
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
(1) Disconnect battery negative cable.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(4) Rotate crankshaft to align timing marks (Fig.
75) to #1 TDC.
(5) Remove camshaft sprocket attaching bolt and
remove timing chain with crankshaft and camshaft
sprockets.
(6) Slip crankshaft sprocket onto crankshaft and
compress tensioner shoe by placing a large screw-
driver between crankshaft sprocket and tensioner
shoe (Fig. 74). Compress shoe until hole in shoe lines
up with hole in bracket. Slide a suitable pin into the
holes (Fig. 74) and remove screwdriver.(7) If tensioner assembly is to be replaced, remove
the three tensioner to block bolts and remove ten-
sioner assembly.
Fig. 74 Compressing Tensioner For Chain
Installation
1 - SCREWDRIVER
2 - INSERT PIN HERE
Fig. 75 Alignment of Timing Marks
1 - TIMING MARKS
BR/BEENGINE 3.9L 9 - 57
TIMING BELT / CHAIN COVER(S) (Continued)

INSPECTIONÐMEASURING TIMING CHAIN
STRETCH
NOTE: Timing chain tensioner must be removed for
this operation.
(1) Place a scale next to the timing chain so that
any movement of the chain can be measured.
(2) Place a torque wrench and socket over cam-
shaft sprocket attaching bolt. Apply torque in the
direction of crankshaft rotation to take up slack; 41
N´m (30 ft. lbs.) torque with cylinder head installed
or 20 N´m (15 ft. lbs.) torque with cylinder head
removed. With torque applied to the camshaft
sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block the crankshaft to
prevent rotation.
(3) Hold a scale with dimensional reading even
with the edge of a chain link. With cylinder heads
installed, apply 14 N´m (30 ft. lbs.) torque in the
reverse direction. With the cylinder heads removed,
apply 20 N´m (15 ft. lbs.) torque in the reverse direc-
tion. Note the amount of chain movement (Fig. 76).
(4) Install a new timing chain, if its movement
exceeds 3.175 mm (1/8 inch).
INSTALLATION
(1) If tensioner assembly is being replaced, install
tensioner and mounting bolts. Torque bolts to 24 N´m
(210 in. lbs.).
(2) 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.
(3) Place timing chain around both sprockets.
(4) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).(5) Slide both sprockets evenly over their respec-
tive shafts and verify alignment of timing marks
(Fig. 77) with a straight-edge if necessary.
(6) Install the camshaft bolt. Tighten the bolt to 68
N´m (50 ft. lbs.) torque.
(7)Remove tensioner pin.Again, verify align-
ment of timing marks.
(8) Install timing cover (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- INSTALLATION).
(9) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(10) Connect battery negative cable.
(11) Start engine and check for oil and coolant
leaks.
Fig. 76 Measuring Timing Chain Wear and Stretch
1 - TORQUE WRENCH
2 - 3.175 MM
(0.125 IN.)
Fig. 77 Alignment of Timing Marks
1 - TIMING MARKS
9 - 58 ENGINE 3.9LBR/BE
TIMING BELT/CHAIN AND SPROCKETS (Continued)

ENGINE 5.2L
TABLE OF CONTENTS
page page
ENGINE 5.2L
DESCRIPTION...........................60
DIAGNOSIS AND TESTING.................61
ENGINE DIAGNOSIS - INTRODUCTION......61
PERFORMANCE.......................61
MECHANICAL.........................63
LUBRICATION.........................66
CYLINDER COMPRESSION PRESSURE.....67
CYLINDER COMBUSTION PRESSURE
LEAKAGE.............................67
STANDARD PROCEDURE..................68
FORM-IN-PLACE GASKETS AND SEALERS. . . 68
REPAIR DAMAGED OR WORN THREADS....68
HYDROSTATIC LOCK....................68
CYLINDER BORE HONING...............69
REMOVAL..............................69
INSTALLATION...........................70
SPECIFICATIONS........................72
SPECIAL TOOLS.........................77
CYLINDER HEAD
DESCRIPTION...........................79
OPERATION.............................79
DIAGNOSIS AND TESTING.................79
CYLINDER HEAD GASKET FAILURE........79
REMOVAL..............................80
CLEANING..............................80
INSPECTION............................80
INSTALLATION...........................80
CYLINDER HEAD COVER(S)
REMOVAL..............................81
CLEANING..............................81
INSPECTION............................81
INSTALLATION...........................81
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION...........................81
STANDARD PROCEDURE..................82
VALVES, GUIDES AND SPRINGS...........82
REMOVAL..............................84
CLEANING..............................84
INSPECTION............................84
INSTALLATION...........................85
ROCKER ARM / ADJUSTER ASSEMBLY
REMOVAL..............................85
INSTALLATION...........................85
ENGINE BLOCK
CLEANING..............................86
INSPECTION............................86
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL..............................86INSTALLATION...........................87
CONNECTING ROD BEARINGS
STANDARD PROCEDURE..................88
CONNECTING ROD BEARING FITTING......88
CRANKSHAFT
DESCRIPTION...........................88
OPERATION.............................88
REMOVAL..............................88
INSTALLATION...........................89
CRANKSHAFT MAIN BEARINGS
DESCRIPTION...........................90
OPERATION.............................90
STANDARD PROCEDURE..................90
CRANKSHAFT MAIN BEARING FITTING.....90
REMOVAL..............................90
INSTALLATION...........................90
CRANKSHAFT OIL SEAL - FRONT
DESCRIPTION...........................91
OPERATION.............................91
REMOVAL..............................91
INSTALLATION...........................91
CRANKSHAFT OIL SEAL - REAR
DESCRIPTION...........................91
OPERATION.............................92
REMOVAL..............................92
INSTALLATION...........................92
DISTRIBUTOR BUSHING
REMOVAL..............................94
INSTALLATION...........................94
HYDRAULIC LIFTERS (CAM IN BLOCK)
DIAGNOSIS AND TESTING.................95
HYDRAULIC TAPPETS...................95
REMOVAL..............................96
CLEANING..............................96
INSTALLATION...........................96
PISTON & CONNECTING ROD
DESCRIPTION...........................97
STANDARD PROCEDURE..................97
PISTON FITTING.......................97
REMOVAL..............................97
CLEANING..............................98
INSPECTION............................98
INSTALLATION...........................98
PISTON RINGS
STANDARD PROCEDURE..................98
PISTON RING FITTING..................98
VIBRATION DAMPER
REMOVAL..............................99
INSTALLATION...........................99
BR/BEENGINE 5.2L 9 - 59