2001 DODGE RAM engine oil

COOLING
TABLE OF CONTENTS
page page
COOLING
DESCRIPTION............................1
OPERATION.............................2
DIAGNOSIS AND TESTING..................4
PRELIMINARY CHECKS...................4
ON-BOARD DIAGNOSTICS (OBD)...........4
COOLING SYSTEM LEAKS................5
COOLING SYSTEM GAS ENGINE...........7
COOLING SYSTEM DIESEL ENGINE........12
STANDARD PROCEDURE..................15
DRAINING COOLING SYSTEM - 3.9L/5.2L/
5.9L/8.0L ENGINES......................15
DRAINING COOLING SYSTEM - 5.9L
DIESEL ENGINE........................15REFILLING COOLING SYSTEM - 3.9L/5.2L/
5.9L/8.0L ENGINES......................15
REFILLING COOLING SYSTEM - 5.9L
DIESEL ENGINE........................15
ADDING ADDITIONAL COOLANT...........16
COOLANT LEVEL CHECK................16
COOLING SYSTEM CLEANING/REVERSE
FLUSHING............................16
COOLANT SELECTION-ADDITIVES.........17
SPECIFICATIONS........................17
SPECIAL TOOLS.........................18
ACCESSORY DRIVE......................19
ENGINE................................39
TRANSMISSION.........................79
COOLING
DESCRIPTIONÐCOOLING SYSTEM FLOW -
3.9L/5.2L/5.9L ENGINE
The cooling system regulates engine operating tem-
perature. It allows the engine to reach normal oper-
ating temperature as quickly as possible. It also
maintains normal operating temperature and pre-
vents overheating.
The cooling system also provides a means of heat-
ing the passenger compartment and cooling the auto-
matic transmission fluid (if equipped). The cooling
system is pressurized and uses a centrifugal water
pump to circulate coolant throughout the system.
An optional factory installed maximum duty cool-
ing package is available on most models. This pack-
age will provide additional cooling capacity forvehicles used under extreme conditions such as
trailer towing in high ambient temperatures (Fig. 1).
DESCRIPTIONÐCOOLING SYSTEM FLOW -
5.9L DIESEL
The diesel engine cooling system consists of (Fig.
2):
²Cross-flow radiator
²Belt driven water pump
²Belt driven mechanical cooling fan
²Thermal viscous fan drive
²Fan shroud
²Radiator pressure cap
²Vertically mounted thermostat
²Coolant reserve/recovery system
²Transmission oil cooler
²Coolant
BR/BECOOLING 7 - 1

Coolant flow circuits for the 5.9L diesel engine are
shown in (Fig. 3).
DESCRIPTIONÐHOSE CLAMPS
The cooling system utilizes both worm drive and
spring type hose clamps. If a spring type clamp
replacement is necessary, replace with the original
Mopartequipment spring type clamp.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 4).
OPERATIONÐHOSE CLAMPS
The worm type hose clamp uses a specified torque
value to maintain proper tension on a hose connec-
tion.
The spring type hose clamp applies constant ten-
sion on a hose connection. To remove a spring type
hose clamp, only use constant tension clamp pliers
designed to compress the hose clamp.
Fig. 1 Engine Cooling System Flow
1 - HEATER
2 - BYPASS*3 - CROSSFLOW RADIATOR
Fig. 2 Cooling System Components 5.9L Diesel
Engine
1 - RADIATOR CAP
2 - AUXILIARY TRANSMISSION OIL COOLER
3 - CHARGE AIR COOLER
4 - RADIATOR LOWER HOSE
5 - OVERFLOW/RESERVOIR BOTTLE
6 - FAN SHROUD
7 - RADIATOR UPPER HOSE
8 - CONSTANT TENSION CLAMP
7 - 2 COOLINGBR/BE
COOLING (Continued)

hoses, gasket edges and heater. Seal small leak holes
with a Sealer Lubricant (or equivalent). Repair leak
holes and inspect system again with pressure
applied.
Drops Quickly:Indicates that serious leakage is
occurring. Examine system for external leakage. If
leaks are not visible, inspect for internal leakage.
Large radiator leak holes should be repaired by a
reputable radiator repair shop.
INTERNAL LEAKAGE INSPECTION
Remove engine oil pan drain plug and drain a
small amount of engine oil. If coolant is present in
the pan, it will drain first because it is heavier than
oil. An alternative method is to operate engine for a
short period to churn the oil. After this is done,
remove engine dipstick and inspect for water glob-
ules. Also inspect transmission dipstick for water
globules and transmission fluid cooler for leakage.
WARNING: WITH RADIATOR PRESSURE TESTER
TOOL INSTALLED ON RADIATOR, DO NOT ALLOW
PRESSURE TO EXCEED 110 KPA (20 PSI). PRES-
SURE WILL BUILD UP QUICKLY IF A COMBUSTION
LEAK IS PRESENT. TO RELEASE PRESSURE,
ROCK TESTER FROM SIDE TO SIDE. WHEN
REMOVING TESTER, DO NOT TURN TESTER MORE
THAN 1/2 TURN IF SYSTEM IS UNDER PRESSURE.
Operate engine without pressure cap on radiator
until thermostat opens. Attach a Pressure Tester to
filler neck. If pressure builds up quickly it indicates a
combustion leak exists. This is usually the result of a
cylinder head gasket leak or crack in engine. Repair
as necessary.
If there is not an immediate pressure increase,
pump the Pressure Tester. Do this until indicated
pressure is within system range of 110 kPa (16 psi).
Fluctuation of gauge pointer indicates compression or
combustion leakage into cooling system.
Because the vehicle is equipped with a catalytic
converter,do notremove spark plug cables or short
out cylinders to isolate compression leak.If the needle on dial of pressure tester does not
fluctuate, race engine a few times to check for an
abnormal amount of coolant or steam. This would be
emitting from exhaust pipe. Coolant or steam from
exhaust pipe may indicate a faulty cylinder head gas-
ket, cracked engine cylinder block or cylinder head.
A convenient check for exhaust gas leakage into
cooling system is provided by a commercially avail-
able Block Leak Check tool. Follow manufacturers
instructions when using this product.COMBUSTION LEAKAGE TESTÐWITHOUT
PRESSURE TESTER
DO NOT WASTE reusable coolant. If solution is
clean, drain coolant into a clean container for reuse.
WARNING: DO NOT REMOVE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Drain sufficient coolant to allow thermostat
removal. (Refer to 7 - COOLING/ENGINE/ENGINE
COOLANT THERMOSTAT - REMOVAL). Remove
accessory drive belt (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - REMOVAL).
Add coolant to radiator to bring level to within 6.3
mm (1/4 in) of top of thermostat housing.
CAUTION: Avoid overheating. Do not operate
engine for an excessive period of time. Open drain-
cock immediately after test to eliminate boil over.
Start engine and accelerate rapidly three times, to
approximately 3000 rpm while observing coolant. If
internal engine combustion gases are leaking into
cooling system, bubbles will appear in coolant. If bub-
bles do not appear, internal combustion gas leakage
is not present.
7 - 6 COOLINGBR/BE
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
5. Pressure cap not installed tightly. If cap
is loose, boiling point of coolant will be
lowered. Also refer to the following Step
6.5. Tighten cap
6. Poor seals at the radiator cap. 6. (a) Check condition of cap and cap
seals. Refer to Radiator Cap. Replace
cap if necessary.
(b) Check condition of radiator filler neck.
If neck is bent or damaged, replace
radiator.
7. Coolant level low in radiator but not in
coolant reserve/overflow tank. This
means the radiator is not drawing coolant
from the coolant reserve/overflow tank as
the engine cools7. (a) Check condition of radiator cap and
cap seals. Refer to Radiator Cap in this
Group. Replace cap if necessary.
(b) Check condition of radiator filler neck.
If neck is bent or damaged, replace
radiator.
(c) Check condition of the hose from the
radiator to the coolant tank. It should fit
tight at both ends without any kinks or
tears. Replace hose if necessary.
(d) Check coolant reserve/overflow tank
and tanks hoses for blockage. Repair as
necessary.
8. Incorrect coolant concentration 8. Check coolant. (Refer to
LUBRICATION & MAINTENANCE/FLUID
TYPES - DESCRIPTION).
9. Coolant not flowing through system 9. Check for coolant flow at radiator filler
neck with some coolant removed, engine
warm and thermostat open. Coolant
should be observed flowing through
radiator. If flow is not observed, determine
area of obstruction and repair as
necessary.
10. Radiator or A/C condenser fins are
dirty or clogged.10. Remove insects and debris. (Refer to
7 - COOLING - STANDARD
PROCEDURE).
11. Radiator core is corroded or plugged. 11. Have radiator re-cored or replaced.
12. Aftermarket A/C installed without
proper radiator.12. Install proper radiator.
13. Fuel or ignition system problems. 13. Refer to 14 - Fuel System or 8 -
Electrical for diagnosis and testing
procedures.
14. Dragging brakes. 14. Check and correct as necessary.
(Refer to 5 - BRAKES - DIAGNOSIS AND
TESTING) for correct procedures.
15. Bug screen or cardboard is being
used, reducing airflow.15. Remove bug screen or cardboard.
7 - 8 COOLINGBR/BE
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
16. Thermostat partially or completely
shut.16. Check thermostat operation and
replace as necessary. (Refer to 7 -
COOLING/ENGINE/ENGINE COOLANT
THERMOSTAT - REMOVAL) .
17. Viscous fan drive not operating
properly.17. Check fan drive operation and replace
as necessary. (Refer to 7 - COOLING/
ENGINE/FAN DRIVE VISCOUS CLUTCH
- REMOVAL) .
18. Cylinder head gasket leaking. 18. Check for cylinder head gasket leaks.
(Refer to 7 - COOLING - DIAGNOSIS
AND TESTING).
19. Heater core leaking. 19. Check heater core for leaks. (Refer to
24 - HEATING & AIR CONDITIONING/
PLUMBING - DIAGNOSIS AND
TESTING). Repair as necessary.
TEMPERATURE
GAUGE READING IS
INCONSISTENT
(FLUCTUATES,
CYCLES OR IS
ERRATIC)1. During cold weather operation, with the
heater blower in the high position, the
gauge reading may drop slightly.1. A normal condition. No correction is
necessary.
2. Temperature gauge or engine mounted
gauge sensor defective or shorted. Also,
corroded or loose wiring in this circuit.2. Check operation of gauge and repair if
necessary. (Refer to 8 - ELECTRICAL/
INSTRUMENT CLUSTER - DIAGNOSIS
AND TESTING).
3. Gauge reading rises when vehicle is
brought to a stop after heavy use (engine
still running)3. A normal condition. No correction is
necessary. Gauge should return to normal
range after vehicle is driven.
4. Gauge reading high after re-starting a
warmed up (hot) engine.4. A normal condition. No correction is
necessary. The gauge should return to
normal range after a few minutes of
engine operation.
5. Coolant level low in radiator (air will
build up in the cooling system causing
the thermostat to open late).5. Check and correct coolant leaks. (Refer
to 7 - COOLING - DIAGNOSIS AND
TESTING).
6. Cylinder head gasket leaking allowing
exhaust gas to enter cooling system
causing a thermostat to open late.6. (a) Check for cylinder head gasket
leaks. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
(b) Check for coolant in the engine oil.
Inspect for white steam emitting from the
exhaust system. Repair as necessary.
7. Water pump impeller loose on shaft. 7. Check water pump and replace as
necessary. (Refer to 7 - COOLING/
ENGINE/WATER PUMP - REMOVAL).
8. Loose accessory drive belt. (water
pump slipping)8. (Refer to 7 - COOLING/ACCESSORY
DRIVE/DRIVE BELTS - DIAGNOSIS AND
TESTING). Check and correct as
necessary.
9. Air leak on the suction side of the
water pump allows air to build up in
cooling system causing thermostat to
open late.9. Locate leak and repair as necessary.
BR/BECOOLING 7 - 9
COOLING (Continued)

ACCESSORY DRIVE
TABLE OF CONTENTS
page page
BELT TENSIONERS - 3.9L/5.2L/5.9L
DESCRIPTION...........................19
OPERATION.............................19
REMOVAL..............................20
INSTALLATION...........................20
BELT TENSIONERS - 8.0L
DESCRIPTION...........................20
OPERATION.............................20
REMOVAL..............................21
INSTALLATION...........................22
BELT TENSIONERS - 5.9L DIESEL
DESCRIPTION...........................23
OPERATION.............................23
REMOVAL..............................23
INSTALLATION...........................23
DRIVE BELTS - 3.9L/5.2L/5.9L
DIAGNOSIS AND TESTING.................24
ACCESSORY DRIVE BELT................24
REMOVAL..............................26INSTALLATION...........................27
DRIVE BELTS - 8.0L
DIAGNOSIS AND TESTING.................27
ACCESSORY DRIVE BELT................27
REMOVAL..............................30
INSTALLATION...........................30
DRIVE BELTS - 5.9L DIESEL
DIAGNOSIS AND TESTING.................31
ACCESSORY DRIVE BELT................31
REMOVAL..............................33
INSTALLATION...........................34
VACUUM PUMP - 5.9L DIESEL
DESCRIPTION...........................34
OPERATION.............................35
DIAGNOSIS AND TESTING.................35
VACUUM PUMP OUTPUT.................35
REMOVAL..............................35
INSTALLATION...........................37
BELT TENSIONERS - 3.9L/5.2L/
5.9L
DESCRIPTION
Correct drive belt tension is required to ensure
optimum performance of the belt driven engine acces-
sories. If specified tension is not maintained, belt
slippage may cause; engine overheating, lack of
power steering assist, loss of air conditioning capac-
ity, reduced generator output rate, and greatly
reduced belt life.
It is not necessary to adjust belt tension on the
3.9L/5.2L or 5.9L engines. These engines are
equipped with an automatic belt tensioner (Fig. 1).
The tensioner maintains correct belt tension at all
times. Due to use of this belt tensioner, do not
attempt to use a belt tension gauge on 3.9L/5.2L or
5.9L engines.
OPERATION
The automatic belt tensioner maintains belt ten-
sion by using internal spring pressure, a pivoting
arm and pulley to press against the drive belt.
Fig. 1 Automatic Belt TensionerÐ5.2L and 5.9L
Engines
1 - AUTOMATIC TENSIONER
2 - COIL AND BRACKET
3 - SCREW AND WASHER
BR/BEACCESSORY DRIVE 7 - 19

REMOVAL
WARNING: BECAUSE OF HIGH SPRING PRES-
SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO-
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY (EXCEPT FOR PULLEY).
(1) Remove accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Disconnect wiring and secondary cable from
ignition coil.
(3) Remove ignition coil from coil mounting
bracket (two bolts). Do not remove coil mounting
bracket from cylinder head.
(4) Remove tensioner assembly from mounting
bracket (one nut) (Fig. 2).(5) Remove pulley bolt. Remove pulley from ten-
sioner.
INSTALLATION
(1) Install pulley and pulley bolt to tensioner.
Tighten bolt to 61 N´m (45 ft. lbs.) torque.
(2) Install tensioner assembly to mounting
bracket. An indexing tab is located on back of ten-
sioner. Align this tab to slot in mounting bracket.
Tighten nut to 67 N´m (50 ft. lbs.) torque.
(3) Connect all wiring to ignition coil.
CAUTION: To prevent damage to coil case, coil
mounting bolts must be torqued.
(4) Install coil to coil bracket. If nuts and bolts are
used to secure coil to coil bracket, tighten to 11 N´m
(100 in. lbs.) torque. If coil mounting bracket has
been tapped for coil mounting bolts, tighten bolts to 5
N´m (50 in. lbs.) torque.
(5) Install drive belt. (Refer to 7 - COOLING/AC-
CESSORY DRIVE/DRIVE BELTS - INSTALLA-
TION).
(6) Check belt indexing marks (Fig. 2).
BELT TENSIONERS - 8.0L
DESCRIPTION
CAUTION: Do not attempt to check belt tension with
a belt tension gauge on vehicles equipped with an
automatic belt tensioner.
Drive belts on 8.0L engines are equipped with a
spring loaded automatic belt tensioner (Fig. 3). This
belt tensioner will be used with all belt configura-
tions, such as with or without power steering or air
conditioning.
The tensioner is equipped with an indexing arrow
(Fig. 4) on back of tensioner and an indexing mark
on tensioner housing.
OPERATION
WARNING: THE AUTOMATIC BELT TENSIONER
ASSEMBLY IS SPRING LOADED. DO NOT ATTEMPT
TO DISASSEMBLE THE TENSIONER ASSEMBLY.
The automatic belt tensioner maintains correct belt
tension using a coiled spring within the tensioner
housing. The spring applies pressure to the tensioner
arm pressing the arm into the belt, tensioning the
belt.Fig. 2 Tensioner Indexing Marks and Mounting Nut
1 - TENSIONER ASSEMBLY
2 - TENSIONER MOUNTING NUT
3 - INDEXING ARROW
4 - INDEXING MARK
7 - 20 ACCESSORY DRIVEBR/BE
BELT TENSIONERS - 3.9L/5.2L/5.9L (Continued)

BELT TENSIONERS - 5.9L
DIESEL
DESCRIPTION
Drive belts on all engines are equipped with a
spring loaded automatic belt tensioner (Fig. 9). This
tensioner maintains constant belt tension at all times
and requires no maintenance or adjustment.
CAUTION: Do not attempt to check belt tension with
a belt tension gauge on vehicles equipped with an
automatic belt tensioner.
OPERATION
WARNING: THE AUTOMATIC BELT TENSIONER
ASSEMBLY IS SPRING LOADED. DO NOT ATTEMPT
TO DISASSEMBLE THE TENSIONER ASSEMBLY.
The automatic belt tensioner maintains correct belt
tension using a coiled spring within the tensioner
housing. The spring applies pressure to the tensioner
arm pressing the arm into the belt, tensioning the
belt.
If a new belt is being installed, the arrow must be
within approximately 3 mm (1/8 in.) of indexing
mark. Belt is considered new if it has been used 15
minutes or less. If this specification cannot be met,
check for:
²The wrong belt being installed (incorrect length/
width)
²Worn bearings on an engine accessory (A/C com-
pressor, power steering pump, water pump, idler pul-
ley or generator)
²A pulley on an engine accessory being loose
²Misalignment of an engine accessory
²Belt incorrectly routed.
REMOVAL
WARNING: BECAUSE OF HIGH SPRING PRES-
SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO-
MATIC TENSIONER. UNIT IS SERVICED AS AN
ASSEMBLY.
(1) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove tensioner mounting bolt (Fig. 10) and
remove tensioner.
INSTALLATION
(1) Install tensioner assembly to mounting
bracket. A dowel is located on back of tensioner. Align
this dowel to hole in tensioner mounting bracket.
Tighten bolt to 41 N´m (30 ft. lbs.) torque.
(2) Install drive belt (Refer to 7 - COOLING/AC-
CESSORY DRIVE/DRIVE BELTS - INSTALLA-
TION).
Fig. 8 Tensioner Dowel Hole
1 - DOWEL PIN HOLE
2 - TENSIONER MOUNTING BRACKET
Fig. 9 Belt
1 - WATER PUMP
2 - ACCESSORY DRIVE BELT
3 - AUTOMATIC BELT TENSIONER
4 - 3/89SQUARE BOLT
5 - MOUNT. BOLT
BR/BEACCESSORY DRIVE 7 - 23
BELT TENSIONERS - 8.0L (Continued)