2001 DODGE RAM lock

INSTALLATION
(1) Install the plunger, spring, and plug as shown
in (Fig. 152). Tighten the plug to 80 N´m (60 ft. lbs.)
torque.
(2) Connect the battery negative cables.
(3) Start the engine and verify that it has oil pres-
sure.
OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
The 3±wire, solid-state oil pressure sensor is
installed into the oil pressure galley on the engine
block. It is located below and to the rear of the
Engine Control Module (ECM) (Fig. 154).
OPERATION
Operation of the oil pressure sensor on the
diesel engine is controlled by the Engine Con-
trol Module (ECM). The Powertrain Control
Module (PCM) does not have any control over
the sensor.The oil pressure sensor uses three circuits. They
are:
²A 5±volt power supply from the ECM
²A sensor ground through the ECM's sensor
return
²A signal to the ECM relating to engine oil pres-
sure
The oil pressure sensor has a 3±wire electrical
function very much like the Manifold Absolute Pres-
sure (MAP) sensor on the gasoline powered engine.
Meaning different pressures relate to different output
voltages.
A 5±volt supply is sent to the sensor from the ECM
to power up the sensor. The sensor returns a voltage
signal back to the ECM relating to engine oil pres-
sure. This signal is then transferred (bussed) to the
instrument panel on the CCD bus circuit to operate
the oil pressure gauge and the check gauges lamp.
Ground for the sensor is provided by the ECM
through a low-noise sensor return.
REMOVAL
(1) Disconnect the battery negative cables.
(2) Disconnect the oil pressure sensor connector
(Fig. 155).
(3) Using a suitable socket, remove the oil pres-
sure sensor from the block (counter-clockwise).
Fig. 154 Oil Pressure Sensor (Engine) Location
1 - ENGINE OIL PRESSURE SENSOR
2 - ELECTRIAL CONNECTOR
3 - ECM
Fig. 155 Oil Pressure Sensor Location
1 - ENGINE OIL PRESSURE SENSOR
2 - ELECTRIAL CONNECTOR
3 - ECM
9 - 298 ENGINE 5.9L DIESELBR/BE
OIL PRESSURE RELIEF VALVE (Continued)

INSTALLATION
(1) If the sensor is not being replaced, inspect the
o-ring (Fig. 156) and replace if necessary.
(2) Install the oil pressure sensor and tighten to 16
N´m (144 in. lbs.) torque.
(3) Connect the battery negative cables.
(4) Start engine and check for oil leaks at the sen-
sor.
OIL PUMP
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove fan/drive assembly (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL).
(3) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(4) Remove the fan support/hub assembly.
(5) Remove crankshaft damper (Fig. 157) (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(6) Remove the gear housing cover (Fig. 158)
(Refer to 9 - ENGINE/VALVE TIMING/GEAR HOUS-
ING COVER - REMOVAL).
(7) Remove the four mounting bolts and pull the
pump from the bore in the cylinder block (Fig. 159).
CLEANING
Clean all parts in solvent and dry with compressed
air. Clean the old sealer residue from the back of the
gear housing cover and front of the gear housing.
INSPECTION
Disassemble and inspect the oil pump as fol-
lows:
(1) Visually inspect the lube pump gears for chips,
cracks or excessive wear.
(2) Remove the back plate (Fig. 160).
(3) Mark TOP on the gerotor planetary using a felt
tip pen (Fig. 160).
(4) Remove the gerotor planetary (Fig. 160).
Inspect for excessive wear or damage. Inspect the
pump housing and gerotor drive for damaged and
excessive wear.
(5) Install the gerotor planetary in the original
position. The chamfer must be on the O.D. and down.
Fig. 156 Oil Pressure Sensor and
1 - ENGINE OIL PRESSURE SENSOR
2 - O-RING
Fig. 157 Crankshaft Damper Removal/Installation
1 - DAMPER
2 - BOLT
Fig. 158 Gear Housing and Cover
1 - GEAR HOUSING
2 - GEAR HOUSING COVER
BR/BEENGINE 5.9L DIESEL 9 - 299
OIL PRESSURE SENSOR/SWITCH (Continued)

(6) Measure the tip clearance (Fig. 161). Maximum
clearance is 0.1778 mm (0.007 inch). If the oil pump
is out of limits, replace the pump.
(7) Measure the clearance of the gerotor drive/
gerotor planetary to port plate (Fig. 162). Maximum
clearance is 0.127 mm (0.005 inch). If the oil pump is
out of limits, replace the pump.
(8) Measure the clearance of the gerotor planetary
to the body bore (Fig. 163). Maximum clearance is
0.381 mm (0.015 inch). If the oil pump is out of lim-
its, replace the pump.
(9) Measure the gears backlash (Fig. 164). The
limits of a used pump is 0.075- 0.85 mm (0.0296-
0.0335 inch). If the backlash is out of limits, replace
the oil pump.
(10) Install the back plate.
INSTALLATION
(1) Lubricate the pump with clean engine oil. Fill-
ing the pump with clean engine oil during installa-
tion will help to prime the pump at engine start up.
(2) Verify the idler gear pin is installed in the
locating bore in the cylinder block.
(3) Install the pump (Fig. 159). Tighten the oil
pump mounting bolts in two steps, in the sequence
shown in (Fig. 165).
²Step 1ÐTighten to 5 N´m (44 in. lbs.) torque.
²Step 2ÐTighten to 24 N´m (18 ft. lbs.) torque.
(4) The back plate on the pump seats against the
bottom of the bore in the cylinder block. When the
pump is correctly installed, the flange on the pump
will not touch the cylinder block.
(5) Measure the idler gear to pump drive gear
backlash and the idler gear to crankshaft gear back-
lash (Fig. 166). The backlash should be 0.75- 0.85mm (0.0296-0.0335 inch). If the backlash is out of
limits, replace the oil pump.
(6) If the adjoining gear moves when you measure
the backlash, the reading will be incorrect.
Fig. 159 Oil Pump Removal/Installation
1 - OIL PUMP
2 - BOLT (4)
Fig. 160 Gerotor Planetary and Gerotor
1 - OIL PUMP BACK PLATE
2 - GEROTOR
3 - GEROTOR PLANETARY
Fig. 161 Measuring Tip Clearance
1 - FEELER GAUGE
Fig. 162 Measuring Gerotor to Port Plate Clearance
1 - PORT PLATE
2 - GEROTOR
9 - 300 ENGINE 5.9L DIESELBR/BE
OIL PUMP (Continued)

(7) Apply a bead of MopartSilicone Rubber Adhe-
sive Sealant or equivalent to the gear housing cover
sealing surface.(8) Install the gear housing cover (Refer to 9 -
ENGINE/VALVE TIMING/GEAR HOUSING COVER
- INSTALLATION).
(9) Install the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(10) Install the fan support/hub assembly and
torque bolts to 24 N´m (18 ft. lbs.).
(11) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(12) Install the cooling fan (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION).
(13) Connect battery negative cables.
(14) Start engine and check for oil leaks.
INTAKE MANIFOLD
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the charge air cooler outlet tube from
the air inlet housing (Fig. 167).
(3) Remove the engine oil dipstick tube mounting
bolt (Fig. 167). Position dipstick tube to the side.
(4) Disconnect the air grid heater power cables at
the cable mounting studs (Fig. 168).
(5) Remove the four (4) air inlet housing mounting
bolts (Fig. 168) and remove the housing from top of
the heater elements.
(6) Remove the intake air grid heater from the
manifold (Fig. 169).
(7) Remove the high pressure fuel lines.(Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES
- REMOVAL).
(8) Remove the remaining intake manifold cover-
to-cylinder head bolts.
(9) Remove the intake manifold cover and gasket.
Keep the gasket material and any other material out
of the air intake.
(10) Clean the intake manifold cover and cylinder
head sealing surface.
Fig. 163 Measuring Gerotor Planetary to Body Bore
Clearance
1 - BODY BORE
2 - GEROTOR PLANETARY
Fig. 164 Measure Gear Backlash
1 - OIL PUMP DRIVE GEAR
2 - IDLER GEAR
3 - BACKLASH
4 - BACKLASH
Fig. 165 Oil Pump Mounting Bolt Torque Sequence
Fig. 166 Idler Gear to Pump Drive Gear and
Crankshaft Gear Backlash
BR/BEENGINE 5.9L DIESEL 9 - 301
OIL PUMP (Continued)

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) Using a new gasket, install the intake manifold
cover.
(2) Install the cover-to-cylinder head bolts that do
not hold down the high pressure fuel line support
brackets. Tighten the bolts to 24 N´m (18 ft. lbs.)
torque.
(3) Install the high pressure fuel lines (Refer to 14
- FUEL SYSTEM/FUEL DELIVERY/FUEL LINES -
INSTALLATION).(4) Install the high pressure fuel line support
bracket-to-intake manifold cover bolts and tighten to
24 N´m (18 ft. lbs.) torque.
Fig. 167 Charge Air Cooler Air Tube
1 - FRONT WIRING CLIP
2 - GROUND CABLE
3 - TUBE BOLT
4 - ENGINE OIL DIPSTICK TUBE
5 - CLAMPS
6 - AIR TUBE (INT. MAN.-TO-INTERCOOLER)
7 - RUBBER HOSE
8 - AIR INTAKE HOUSING
9 - CABLE BRACKET HOUSING
Fig. 168 Air Inlet Housing
1 - GROUND STRAP
2 - AIR INTAKE HOUSING
3 - HEATER POWER CABLE MOUNTING STUDS
4 - FUEL LINE BRACKET BOLT
5 - HOUSING BOLTS (4)
Fig. 169 Intake Air Grid Heater
1 - AIR HEATER ELEMENTS
2 - LOWER GASKET
3 - BLOCK
4 - UPPER GASKET
9 - 302 ENGINE 5.9L DIESELBR/BE
INTAKE MANIFOLD (Continued)

(10) Remove the exhaust manifold-to-cylinder head
bolts and spacers (Fig. 173).
(11) Remove the exhaust manifold and gaskets
(Fig. 173).
CLEANING
Clean the cylinder head and exhaust manifold seal-
ing surfaces with a suitable scraper. Use a Scotch-
BriteŸ pad or equivalent.
INSPECTION
Inspect the exhaust manifold for cracks. Measure
the exhaust manifold for flatness. Place a ruler over
all of the exhaust ports and insert a feeler gauge
between the port flange and the ruler.
INSTALLATION
(1) Using new gaskets, install the exhaust mani-
fold and gaskets. Install the bolts and spacers and
tighten the bolts in the sequence shown in (Fig. 173)
to 43 N´m (32 ft. lbs.) torque.
(2) Install the cab heater return hose to the man-
ifold bolt stud. Tighten the nut to 24 N´m (18 ft. lbs.)
torque.
(3) Install the turbocharger. Apply anti-seize to the
studs and then tighten the turbocharger mounting
nuts to 32 N´m (24 ft. lbs.) torque.(4) Install the oil drain tube and oil supply line to
the turbocharger. Tighten the drain tube bolts to 24
N´m (18 ft. lbs.) torque.
(5)Pre-lube the turbocharger.Pour 50 to 60 cc
(2 to 3 oz.) clean engine oil in the oil supply line fit-
ting. Rotate the turbocharger impeller by hand to
distrubute the oil thoroughly.
(6) Install and tighten the oil supply line fitting
nut to 20 N´m (133 in. lbs.) torque.
(7) Position the charge air cooler inlet pipe to the
turbocharger. With the clamp in position, tighten the
clamp nut to 8 N´m (72 in. lbs.) torque.
(8) Position the air inlet hose to the turbocharger
(Fig. 171). Tighten the clamp to 8 N´m (72 in. lbs.)
torque.
(9) Raise vehicle on hoist.
(10) Connect the exhaust pipe to the turbocharger
(Fig. 170) and tighten the bolts to 34 N´m (25 ft. lbs.)
torque.
(11) Lower the vehicle.
(12) Connect the battery negative cables.
(13) Start the engine to check for leaks.
GEAR HOUSING
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Remove the oil pan and suction tube (Refer to 9
- ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(4) Partially drain engine coolant into container
suitable for re-use (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(5) Lower vehicle.
(6) Remove radiator upper hose.
(7) Disconnect coolant recovery bottle hose from
radiator filler neck and lift bottle off of fan shroud.
(8) Disconnect windshield washer pump supply
hose and electrical connections and lift washer bottle
off of fan shroud.
(9) Remove the fan shroud-to-radiator mounting
bolts.
(10) Remove viscous fan/drive assembly (Refer to 7
- COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(11) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(12) Remove the cooling fan support/hub from the
front of the engine (Fig. 174).
(13) Raise the vehicle on hoist.
(14) Remove the crankshaft damper (Fig. 175)
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(15) Lower the vehicle.
Fig. 173 Exhaust Manifold and Gaskets
9 - 304 ENGINE 5.9L DIESELBR/BE
EXHAUST MANIFOLD (Continued)

(16) Remove the gear cover-to-housing bolts and
gently pry the cover away from the housing (Fig.
176), taking care not to mar the gasket surfaces.
(17) Remove the fuel injection pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - REMOVAL).
(18) Disconnect the camshaft position sensor con-
nector.
(19) Remove the camshaft (Refer to 9 - ENGINE/
ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - REMOVAL).
(20) Remove the gear housing and gasket (Fig.
177).(21) Clean the gasket material from the cylinder
block.
INSTALLATION
(1) Install a new gasket and the gear housing (Fig.
177). Tighten the bolts to 24 N´m (18 ft. lbs.) torque.
(2) Connect the camshaft position sensor connec-
tor.
Fig. 174 Fan Support/Hub AssemblyÐRemoval/
Installation
1 - FAN SUPPORT/HUB
2 - FAN PULLEY
Fig. 175 Crankshaft DamperÐRemoval/Installation
1 - DAMPER
2 - BOLT
Fig. 176 Gear Housing and Cover
1 - GEAR HOUSING
2 - GEAR HOUSING COVER
Fig. 177 Gear Housing and Gasket
1 - DOWEL
2 - GASKET
3 - BOLT
4 - GEAR HOUSING
BR/BEENGINE 5.9L DIESEL 9 - 305
GEAR HOUSING (Continued)

(3) Install the injection pump (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL INJECTION
PUMP - INSTALLATION).
(4) Install the camshaft (Refer to 9 - ENGINE/EN-
GINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - INSTALLATION). Align the crankshaft,
camshaft, and injection pump gear marks as shown
in (Fig. 178).
(5) If a new housing is installed, the camshaft
position sensor must be transferred to the new hous-
ing.
(6) Obtain a seal pilot/installation tool from a
crankshaft front seal service kit and install the pilot
into the crankshaft front oil seal.
(7) Apply a bead of MopartSilicone Rubber Adhe-
sive Sealant or equivalent to the gear housing cover.
Be sure to surround all through holes.
(8) Using the seal pilot to align the cover (Fig.
179), install the cover to the housing and install the
bolts. Tighten the bolts to 24 N´m (18 ft. lbs.) torque.
(9) Remove the seal pilot.
(10) Raise the vehicle.
(11) Trim any excess gear housing gasket to make
it flush with the oil pan rail.
(12) Using a new gasket, install the oil pan and
suction tube (Refer to 9 - ENGINE/LUBRICATION/
OIL PAN - INSTALLATION).
(13) Install the crankshaft damper (Fig. 175)
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
(14) Lower vehicle.
(15) Install the fan support/hub assembly (Fig.
174) and tighten bolts to 24 N´m (18 ft. lbs.) torque.(16) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(17) Install the cooling fan and shroud together
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(18) Install the windshield washer reservoir to the
fan shroud and connect the washer pump supply
hose and electrical connection.
(19) Install the coolant recovery bottle to the fan
shroud and connect the hose to the radiator filler
neck.
(20) Install the radiator upper hose and clamps.
(21) Add engine oil.
(22) Add coolant (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(23) Connect the battery cables.
(24) Start engine and inspect for leaks.
GEAR HOUSING COVER
REMOVAL
(1) Disconnect both battery negative cables.
(2) Raise vehicle on hoist.
(3) Partially drain engine coolant into container
suitable for re-use (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(4) Lower vehicle.
(5) Remove radiator upper hose.
(6) Disconnect coolant recovery bottle hose from
radiator filler neck and lift bottle off of fan shroud.
(7) Disconnect windshield washer pump supply
hose and electrical connections and lift washer bottle
off of fan shroud.
(8) Remove viscous fan/drive assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
Fig. 178 Camshaft/Crankshaft Gear Alignment
Fig. 179 Installing Cover with Seal Pilot
1 - SEAL PILOT
9 - 306 ENGINE 5.9L DIESELBR/BE
GEAR HOUSING (Continued)