2001 DODGE RAM seats

(3) Compress valve springs using Valve Spring
Compressor Tool MD-998772A with Adapter 6716A
and Screw 6765 (Fig. 22). Tap the retainer using a
brass drift and ball peen hammer to loosen locks
away from retainer.
(4) Remove valve retaining locks, valve spring
retainers and valve springs. Check for abnormal
wear, replace as required.
(5) Remove the valve stem seals.(6) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
valve guides. Identify valves to ensure installation in
original location.
CLEANING
Clean valves thoroughly. Discard burned, warped,
or cracked valves.
Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner.
INSPECTION
Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 in.), replace the valve.
Measure valve stem guide clearance as follows:
(1) Install Valve Guide Sleeve Tool C-3973 over
valve stem and install valve (Fig. 23). The special
sleeve places the valve at the correct height for
checking with a dial indicator.
(2) Attach dial indicator Tool C-3339 to cylinder
head and set it at right angles to valve stem being
measured (Fig. 24).
(3) Move valve to and from the indicator. The total
dial indicator reading should not exceed 0.432 mm
(0.017 in.). Ream the guides for valves with oversize
stems if dial indicator reading is excessive or if the
stems are scuffed or scored.
INSTALLATIONÐVALVE STEM SEAL
(1) Install new seal onto valve stem.
(2) Position valve spring onto valve stem.
(3) Position Valve Spring Compressor with Adapter
Studs onto cylinder head
Fig. 20 Valve Spring Compressor MD-998772A with
Adaptor 6716-A and Screw 6765
1 - SPECIAL TOOL MD 998772A
2 - SPECIAL TOOL 6765
3 - SPECIAL TOOL 6716A
4 - AIR HOSE
Fig. 21 Special Studs 6715 for V-10 Engine
1 - SPECIAL TOOL 6715
Fig. 22 Valve Spring Compressor MD-998772A with
Adaptor 6716-A and Screw 6765
1 - SPECIAL TOOL MD 998772A
2 - SPECIAL TOOL 6765
3 - SPECIAL TOOL 6716A
4 - AIR HOSE
9 - 198 ENGINE 8.0LBR/BE
INTAKE/EXHAUST VALVES & SEATS (Continued)

(4) Compress valve spring and install retainer
valve locks.
(5) Remove air hose and adapter from spark plug
hole.
(6) Remove Valve Spring Compressor and Adapter
Studs.
(7) Install rocker arms (Refer to 9 - ENGINE/CYL-
INDER HEAD/ROCKER ARM / ADJUSTER ASSY -
INSTALLATION).
(8) The cylinder head cover gasket can be used
again. Install the gasket onto the head rail.For the
left side the number tab is at the front of
engine with the number up. For the right side
the number tab is at the rear of engine with the
number up.
CAUTION: The cylinder head cover fasteners have a
special plating. DO NOT use alternative fasteners.(9) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION) (Fig. 25).
(10) Install closed crankcase ventilation system.
(11) Connect the evaporation control system.
(12) Install air cleaner.
(13) Connect the negative cable to the battery.
(14) Road test vehicle and check for leaks.
INSTALLATIONÐVALVES AND VALVE SPRINGS
(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) Make sure there are no burrs on valve stems.
(5) Coat valve stems with lubrication oil. Insert
valves into valve guides in cylinder head.
(6) Install new seals on all valve guides(BLACK
on intake and BROWN on exhaust). Install valve
springs and valve retainers.
(7) Compress valve springs with Valve Spring
Compressor Tool MD-998772A and adapter 6716A,
Fig. 23 Positioning Valve with Tool C-3973
1 - VALVE
2 - SPACER TOOL
Fig. 24 Measuring Valve Guide Wear
1 - VALVE
2 - SPECIAL TOOL C-3339
Fig. 25 Cylinder Head Covers
1 - CYLINDER HEAD COVER
2 - CYLINDER HEAD COVER GASKET
BR/BEENGINE 8.0L 9 - 199
INTAKE/EXHAUST VALVES & SEATS (Continued)

install locks and release tool. Tap the retainer with a
brass or heavy plastic hammer to ensure locks have
been seated.
(8) If valves and/or seats were ground, measure
the installed height of springs. Make sure the mea-
surement is taken from bottom of spring seat in cyl-
inder 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 coun-
terbore. Ensure this brings spring height back to nor-
mal, 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch).
(9) Install the cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
ROCKER ARM / ADJUSTER
ASSY
REMOVAL
(1) Disconnect spark plug wires by pulling the boot
straight out in line with plug.
(2) Remove cylinder head cover and gasket (Refer
to 9 - ENGINE/CYLINDER HEAD/CYLINDER
HEAD COVER(S) - REMOVAL).
(3) Remove the rocker arm bolts and the rocker
arm assembly (Fig. 26). Place rocker arm assemblies
on a bench in the same order as removed.
(4) Remove the push rods and place them on a
bench in the same order as removed.
INSTALLATION
CAUTION: DO NOT rotate or crank the engine dur-
ing or immediately after rocker arm installation.
Allow the hydraulic roller tappets adequate time to
bleed down (about 5 minutes).
(1) Install the push rods in the same order as
removed.
(2) Install rocker arm assemblies in the same
order as removed. Tighten the rocker arm bolts to 28
N´m (21 ft. lbs.) torque.
(3) Install cylinder head cover and gasket (Refer to
9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(4) Connect spark plug wires.
ENGINE BLOCK
CLEANING
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leaking.
INSPECTION
Examine block for cracks or fractures.
The cylinder walls should be checked for out-of-
round and taper with Cylinder Bore Indicator Tool,
Special tool 6879 or equivalent. The cylinder block
should be bored and honed with new pistons and
rings fitted if:
²The cylinder bores show more than 0.127 mm
(0.005 inch) out-of-round.
²The cylinder bores show a taper of more than
0.254 mm (0.010 inch).
²The cylinder walls are badly scuffed or scored.
Boring and honing operation should be closely coor-
dinated with the fitting of pistons and rings so spec-
ified clearances may be maintained.
CAMSHAFT & BEARINGS (IN
BLOCK)
REMOVALÐCAMSHAFT BEARINGS
This procedure requires that the engine is removed
from the vehicle.
(1) With engine completely disassembled, drive out
rear cam bearing core hole plug.
NOTE: It is not advisable to attempt to replace cam-
shaft bearings unless special removal and installa-
tion tools are available, such as recommended tool
8544 Camshaft Bushing Remover Installer.
Fig. 26 Rocker Arm
1 - ROCKER ARMS
2 - ROCKER ARM PEDESTALS
3 - RETAINER
9 - 200 ENGINE 8.0LBR/BE
INTAKE/EXHAUST VALVES & SEATS (Continued)

(2) Using recommended tool 8544 Camshaft Bush-
ing Remover Installer, Drive out bearing shells.
REMOVALÐCAMSHAFT
(1) Remove rocker arms and push rods (Refer to 9
- ENGINE/CYLINDER HEAD/ROCKER ARM /
ADJUSTER ASSY - REMOVAL). Identify each part
so it can be installed in its original location.
NOTE: The 4 corner tappets can not be removed
without removing the cylinder heads and gaskets.
However, they can be lifted and retained for cam-
shaft removal.
(2) Remove the Bolts retaining the yoke retaining
spider. Remove the yoke retaining spider, tappet
aligning yokes and tappets.
(3) Remove upper and lower intake manifolds
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - REMOVAL).
(4) Remove timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL) and timing chain and
sprockets (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT/CHAIN AND SPROCKETS -
REMOVAL).
(5) Remove camshaft thrust plate (Fig. 27).
(6) 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 using recom-
mended Tool 8544 Camshaft Bushing Remover
Installer, by sliding the new camshaft bearing shell
over proper adapter.
(2) 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 holesare 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. Using a long bolt, insert the camshaft into
the cylinder block.
NOTE: Whenever an engine has been rebuilt, a new
camshaft and/or new tappets installed, add 1 pint of
MoparTCrankcase Conditioner, or equivalent. The
oil mixture should be left in engine for a minimum
of 805 km (500 miles). Drain at the next normal oil
change.
(2) Install camshaft thrust plate. Tighten the torx
bolts to 22 N´m (16 ft. lbs.) torque.
(3) Check camshaft end play. The end play should
be 0.051-0.152 mm (0.002-0.006 inch) with a new
thrust plate and up to 0.254 mm (0.010 inch) with a
used thrust plate. If not within these limits install a
new thrust plate.
(4) Line up key with keyway in sprocket, then
using Special Tools C-3688, C-3718 and MB990799
install crankshaft timing sprocket. Make sure the
sprocket seats against the crankshaft shoulder (Fig.
28).
Fig. 27 Camshaft
1 - CAMSHAFT
2 - THRUST PLATE
Fig. 28 Crankshaft Sprocket Installation
1 - SPECIAL TOOL C-3688
2 - SPECIAL TOOL C-3718
3 - SPECIAL TOOL MD990799
BR/BEENGINE 8.0L 9 - 201
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

ENGINE 5.9L DIESEL
TABLE OF CONTENTS
page page
ENGINE 5.9L DIESEL
DESCRIPTION..........................231
DIAGNOSIS AND TESTING................232
ENGINE DIAGNOSIS - MECHANICAL.......232
SMOKE DIAGNOSIS CHARTS............234
STANDARD PROCEDURE.................237
FORM-IN-PLACE GASKETS AND SEALERS . . 237
REPAIR DAMAGED OR WORN THREADS . . . 238
HYDROSTATIC LOCK...................238
REMOVAL.............................238
INSTALLATION..........................241
SPECIFICATIONS........................242
SPECIAL TOOLS........................244
ENGINE DATA PLATE
DESCRIPTION..........................244
AIR CLEANER ELEMENT
REMOVAL.............................244
INSTALLATION..........................245
CYLINDER HEAD
DESCRIPTION..........................246
REMOVAL.............................246
CLEANING.............................248
INSPECTION...........................250
INSTALLATION..........................250
CYLINDER HEAD COVER(S)
REMOVAL.............................253
CLEANING.............................253
INSPECTION...........................253
INSTALLATION..........................253
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION..........................253
STANDARD PROCEDURE.................253
VALVES, GUIDES AND SPRINGS..........253
VALVE LASH ADJUSTMENT AND
VERIFICATION........................256
REMOVAL.............................258
INSTALLATION..........................260
ROCKER ARM / ADJUSTER ASSY
DESCRIPTION..........................261
REMOVAL.............................261
CLEANING.............................262
INSPECTION...........................262
INSTALLATION..........................263
ENGINE BLOCK
STANDARD PROCEDURE.................263
CYLINDER BORE REFACING.............263
CYLINDER BORE DE-GLAZE.............264
CYLINDER BORE REPAIR...............265
CAM BORE REPAIR....................267INSPECTION...........................267
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL.............................268
INSPECTION...........................272
INSTALLATION..........................273
CONNECTING ROD BEARINGS
STANDARD PROCEDURE.................274
CONNECTING ROD BEARING AND
CRANKSHAFT JOURNAL CLEARANCE......274
CRANKSHAFT
DESCRIPTION..........................275
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE.................275
MAIN BEARING CLEARANCE............275
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................276
INSTALLATION..........................277
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................278
INSTALLATION..........................278
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL.............................278
INSTALLATION..........................279
SOLID LIFTERS/TAPPETS
REMOVAL.............................280
CLEANING.............................281
INSPECTION...........................281
INSTALLATION..........................281
PISTON & CONNECTING ROD
DESCRIPTION..........................282
STANDARD PROCEDURE.................282
PISTON GRADING....................282
REMOVAL.............................285
CLEANING.............................285
INSPECTION...........................285
INSTALLATION..........................287
PISTON RINGS
STANDARD PROCEDURE.................288
PISTON RINGS - FITTING...............288
VIBRATION DAMPER
REMOVAL.............................289
INSPECTION...........................289
INSTALLATION..........................289
FRONT MOUNT
REMOVAL.............................290
INSTALLATION..........................290
REAR MOUNT
REMOVAL.............................291
INSTALLATION..........................291
BR/BEENGINE 5.9L DIESEL 9 - 229

EXCESSIVE WHITE SMOKE
POSSIBLE CAUSE CORRECTION
Fuel injector protrusion not correct. Check washer (shim) at bottom of fuel injector for
correct thickness. (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/FUEL INJECTOR - INSTALLATION)
Fuel injection pump malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Fuel supply side restriction to transfer pump. Refer to Fuel Transfer Pump Pressure (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL TRANSFER
PUMP - DIAGNOSIS AND TESTING)
Fuel transfer (lift) pump malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information. Also refer to Fuel
Transfer Pump Pressure Testing (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL TRANSFER PUMP -
DIAGNOSIS AND TESTING).
Intake/Exhaust valve adjustments not correct (too tight). (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/
EXHAUST VALVES & SEATS - STANDARD
PROCEDURE).
Intake manifold air temperature sensor malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Intake manifold heater circuit not functioning correctly in
cold weather.A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information. Also check heater
elements for correct operation.
Intake manifold heater elements not functioning
correctly in cold weather.A diagnostic trouble code WILL NOT BE SET if heater
elements are malfunctioning. Refer to NTC tests in
Powertrain Diagnostic Procedures Information.
Internal engine damage (scuffed cylinder). Analyze engine oil and inspect oil filter to locate area of
probable damage.
Restriction in fuel supply side of fuel system. Refer to Fuel Transfer Pump Pressure Testing (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL
TRANSFER PUMP - DIAGNOSIS AND TESTING).
Static timing incorrect. A DTC should have been set. If so, (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJECTION
PUMP - DIAGNOSIS AND TESTING).
EXCESSIVE BLUE SMOKE
POSSIBLE CAUSE CORRECTION
Dirty air cleaner or restricted turbocharger intake duct. Check Filter MinderTat air filter housing. (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
ELEMENT - REMOVAL).
Air leak in boost system between turbocharger
compressor outlet and intake manifold.Service air charge system..
Obstruction in exhaust manifold. Remove exhaust manifold and inspect for blockage
(Refer to 9 - ENGINE/MANIFOLDS/EXHAUST
MANIFOLD - REMOVAL).
Restricted turbocharger drain tube. Remove turbocharger drain tube and remove
obstruction.
Crankcase ventilation system plugged. Inspect crankcase breather and vent tube for sludge
formation or obstructions.
9 - 236 ENGINE 5.9L DIESELBR/BE
ENGINE 5.9L DIESEL (Continued)

EXCESSIVE BLUE SMOKE
POSSIBLE CAUSE CORRECTION
Valve seals are worn, brittle, or improperly installed. Replace valve stem oil seals (Refer to 9 - ENGINE/
CYLINDER HEAD/INTAKE/EXHAUST VALVES &
SEATS - REMOVAL).
Valve stems and/or guides are worn. Remove valves and inspect valves and guides. (Refer
to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
Broken or Improperly installed piston rings. Tear down engine and inspect piston rings.
Excessive piston ring end gap. Remove pistons and measure piston ring end gap
(Refer to 9 - ENGINE/ENGINE BLOCK/PISTON RINGS
- STANDARD PROCEDURE).
Excessive cylinder bore wear and taper. Remove pistons and measure cylinder bore wear and
taper (Refer to 9 - ENGINE/ENGINE BLOCK -
STANDARD PROCEDURE).
Cylinder damage. Remove pistons and inspect cylinder bore for cracks or
porosity. Repair with cylinder liner if necessary. (Refer
to 9 - ENGINE/ENGINE BLOCK - STANDARD
PROCEDURE).
Piston damage. Remove pistons and inspect for cracks, holes. Measure
piston for out-of-round and taper (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON & CONNECTING
ROD - INSPECTION).
Turbocharger failure. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - INSPECTION).
STANDARD PROCEDUREÐFORM-IN-PLACE
GASKETS & SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN II
MopartEngine RTV GEN II is used to seal com-
ponents exposed to engine oil. This material is a spe-
cially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Alwaysinspect the package for the expiration date before
use.
MOPARtATF RTV
MopartATF RTV is a specifically designed black
silicone rubber RTV that retains adhesion and seal-
ing properties to seal components exposed to auto-
matic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKER
MopartGasket Maker is an anaerobic type gasket
material. The material cures in the absence of air
when squeezed between two metallic surfaces. It will
not cure if left in the uncovered tube. The anaerobic
material is for use between two machined surfaces.
Do not use on flexible metal flanges.
MOPARtGASKET SEALANT
MopartGasket Sealant is a slow drying, perma-
nently soft sealer. This material is recommended for
sealing threaded fittings and gaskets against leakage
of oil and coolant. Can be used on threaded and
machined parts under all temperatures. This mate-
rial is used on engines with multi-layer steel (MLS)
cylinder head gaskets. This material also will pre-
BR/BEENGINE 5.9L DIESEL 9 - 237
ENGINE 5.9L DIESEL (Continued)

(3) Lightly lubricate head bolts with engine oil and
install. Using the sequence shown in (Fig. 30),
tighten bolts in the following steps:
(a) Torque bolts to 80 N´m (59 ft. lbs.)
(b) Torque bolts to 105 N´m (77 ft. lbs.)
(c) Re-check all bolts to 105 N´m (77 ft. lbs.)
(d) Tighten all bolts an additional ò turn (90É)
(4) Connect fuel return line at rear of head (Fig.
24). Install both sealing washers and torque banjo
bolt to 24 N´m (18 ft. lbs.).
(5)
Install push rods into their original locations (Fig.
31).Verify that they are seated in the tappets
.
(6) Lubricate valve stem tips and install the cross-
heads in their original locations.
(7)
Lubricate the rocker arms and pedestals and
install them in their original locations (Fig. 32). Install
the bolts and torque them to 36 N´m (27 ft. lbs.).
(8) Verify that the valve lash settings are main-
tained (Refer to 9 - ENGINE/CYLINDER HEAD/IN-
TAKE/EXHAUST VALVES & SEATS - STANDARD
PROCEDURE).
(9) Install cylinder head cover (Fig. 33) (Refer to 9
- ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).(10) Connect the IAT and MAP sensor connectors.
(11) Install the fuel filter canister assembly and
torque mounting bolts to 24 N´m (18 ft. lbs.).
(12) Connect the lift pump to fuel filter low pres-
sure line. Torque fittings to 24 N´m (18 ft. lbs.).
(13) Connect the Water-in-Fuel and Fuel Heater
Element connectors at the filter assembly.
(14) Remove the engine lift bracket at rear of cyl-
inder head.
(15)Install the high pressure fuel lines (Fig.
18) (Fig. 19) as follows:
(a) Lubricate the threads (both ends) of the high
pressure line nuts with diesel fuel or engine oil.
(b) Install the rear line bundle (cyls. #3, 5, and
6), and tighten the threads at the head and pump
by hand.
(c) Torque the connections at the cylinder head
first. Torque connections to 38 N´m (28 ft. lbs.).
(d) Torque the line connections at the injection
pump to 24 N´m (18 ft. lbs.).
Fig. 28 Inspecting Push Rod for Cracks
Fig. 29 Inspecting Push Rod for Flatness
Fig. 30 Cylinder Head Bolt Torque Sequence
Fig. 31 Push Rod Installation
BR/BEENGINE 5.9L DIESEL 9 - 251
CYLINDER HEAD (Continued)