2003 DODGE RAM belt

(9) If required, adjust spark plugs to specifications.
Install the plugs and tighten to 41 N´m (30 ft. lbs.)
torque.
(10) Install coil wire.
(11) Connect heat indicator sending unit wire.
(12) Connect the heater hoses and bypass hose.
(13) Install distributor cap and wires.
(14) Connect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(15) Install the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(16) Install the generator and drive belt (Refer to 7
- COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION). Tighten generator mounting bolt
to 41 N´m (30 ft. lbs.) torque. Tighten the adjusting
strap bolt to 23 N´m (200 in. lbs.) torque.
(17) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts.
(18) Place the cylinder head cover gaskets in posi-
tion and install cylinder head covers (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(19) Install closed crankcase ventilation system.
(20) Connect the evaporation control system.
(21) Reinstall the master cylinder and booster
assembly. Refer to section 5 brakes.
(22) Install the air cleaner.
(23) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(24) Connect the negative cable to the battery.
(25) Start engine check for leaks.
CYLINDER HEAD COVER(S)
REMOVAL
NOTE: A steel backed silicon gasket is used with
the cylinder head cover (Fig. 9). This gasket can be
used again.
(1) Disconnect the negative cable from the battery.
(2) Disconnect the spark plug wires form the spark
plugs and set aside.
(3) Disconnect closed ventilation system and evap-
oration control system from cylinder head cover.
(4) Remove cylinder head cover and gasket.
CLEANING
Clean cylinder head cover gasket surface.
Clean head rail, if necessary.
INSPECTION
Inspect cover for distortion and straighten, if nec-
essary.
Check the gasket for use in head cover installation.
If damaged, use a new gasket.
INSTALLATION
(1) The cylinder head cover gasket can be used
again. Install the gasket onto the head rail.
(2) Position the cylinder head cover onto the gas-
ket. Tighten the bolts to 11 N´m (95 in. lbs.) torque.
(3) Install closed crankcase ventilation system and
evaporation control system.
(4) Connect the spark plug wires to the spark
plugs.
(5) Connect the negative cable to the battery.
Fig. 8 Cylinder Head Bolt Tightening Sequence
Fig. 9 Cylinder Head Cover Gasket
1 - CYLINDER HEAD COVER GASKET
DRENGINE - 5.9L 9 - 245
CYLINDER HEAD (Continued)

(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. 19).
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 Mopart
Stud and 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
NOTE: The camshaft has an integral oil pump and
distributor drive gear (Fig. 20).
(1) Remove the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - REMOVAL).
(2) Remove the A/C Condenser (if equipped)
(3) Remove the engine cover.
(4) Remove intake manifold (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - REMOVAL).
(5) Remove cylinder head covers (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(6) Remove timing case cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL) and timing chain (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL).
(7) Remove rocker arms.
(8) Remove push rods and tappets. Identify each
part so it can be installed in its original location.
(9) Remove distributor and lift out the oil pump
and distributor drive shaft.
(10) Remove camshaft thrust plate, note location of
oil tab (Fig. 21).
(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
(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 Holder Tool C-3509 with
tongue back of distributor drive gear (Fig. 22).
Fig. 19 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
Fig. 20 Camshaft and Sprocket Assembly
1 - THRUST PLATE
2 - OIL PUMP AND DISTRIBUTOR DRIVE GEAR INTEGRAL WITH
CAMSHAFT
3 - CAMSHAFT SPROCKET
9 - 250 ENGINE - 5.9LDR
ENGINE BLOCK (Continued)

(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
installed until the camshaft and crankshaft
sprockets and timing chain have been installed.
(4) Install camshaft thrust plate and chain oil tab.
Make sure tang enters lower right hole in
thrust plate.Tighten bolts to 24 N´m (210 in. lbs.)
torque. Top edge of tab should be flat against thrust
plate in order to catch oil for chain lubrication.(5) Install timing chain and gears (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION).
(6) Measure camshaft end play (Refer to 9 -
ENGINE - SPECIFICATIONS). If not within limits
install a new thrust plate.
(7) Each tappet reused must be installed in the
same position from which it was removed.When
camshaft is replaced, all of the tappets must be
replaced.
(8) Install distributor and distributor drive shaft.
(9) Install push rods and tappets.
(10) Install rocker arms.
(11) Install timing case cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(12) Install cylinder head covers (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(13) Install intake manifold (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSTALLA-
TION).
(14) Install the engine cover.
(15) Install the A/C Condenser (if equipped)
(16) Install the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION).
(17) Start engine 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.
Fig. 21 Timing Chain Oil
1 - THRUST PLATE FRONT SIDE
2 - CHAIN OIL TAB
3 - THRUST PLATE REAR SIDE
Fig. 22 Camshaft Holding Tool C-3509 (Installed
Position)
1 - SPECIAL TOOL C-3509
2 - DRIVE GEAR
3 - DISTRIBUTOR LOCK BOLT
DRENGINE - 5.9L 9 - 251
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

CRANKSHAFT
DESCRIPTION
The crankshaft (Fig. 23) is of a cast nodular steel
splayed type design, with five main bearing journal-
s.The crankshaft is located at the bottom of the
engine block and is held in place with five main bear-
ing caps. The number 3 counterweight is the location
for journal size identification.
OPERATION
The crankshaft transfers force generated by com-
bustion within the cylinder bores to the flywheel or
flexplate.
REMOVAL
NOTE: This procedure can be done in vehicle. How-
ever the transmission must be removed first.
(1) If crankshaft is to be removed while engine is
in vehicle remove the transmission. Refer to 21 -
TRANSMISSION/TRANSAXLE.
(2) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(3) Remove the oil pump from the rear main bear-
ing cap (Refer to 9 - ENGINE/LUBRICATION/OIL
PUMP - REMOVAL).
(4) Remove the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(5) Remove the timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(6) Identify rod bearing caps before removal.
Remove rod bearing caps with bearings.CAUTION: Support crankshaft before removing
main bearing caps. failure to do so will allow the
crankshaft to fall damaging the crankshaft.
(7) Using a suitable jack, support the crankshaft.
(8) Identify main bearing caps before removal.
Remove main bearing caps and bearings one at a
time.
(9) Lower the crankshaft out of the block.
(10) Remove and discard the crankshaft rear oil
seals.
(11) Remove and discard the front crankshaft oil
seal.
INSTALLATION
(1) Clean Gasket Maker residue and sealant from
the cylinder block and rear cap mating surface. Do
this before applying the MopartGasket Maker and
the installation of 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 towards 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. 24). DO NOT over apply sealant or
allow the sealant to contact the rubber seal. Assem-
ble bearing cap to cylinder block immediately after
sealant application.
Fig. 23 Crankshaft with Journal Size Identification
Fig. 24 Sealant Application to Bearing Cap
1 - MOPARTGASKET MAKER 5 mm (0.20 IN.) ON BOTH SIDES
OF REAR MAIN CAP
9 - 252 ENGINE - 5.9LDR

(8) 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 2 times for proper engagement.
(9) 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.
(10) Install oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(11) Install the timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(12) Install the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(13) Position the connecting rods onto the crank-
shaft and install the rod bearing caps. Tighten the
nuts to 61 N´m (45 ft. lbs.).
(14) Apply MopartSilicone Rubber Adhesive Seal-
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 25).
Apply enough sealant until a small amount is
squeezed out. Withdraw nozzle and wipe excess seal-
ant off the oil pan seal groove.
(15) Install new front crankshaft oil seal (Refer to
9 - ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - FRONT - INSTALLATION).
(16) Immediately install the oil pan (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
(17) If the transmission was removed, install the
transmission. Refer to 21 - TRANSMISSION/TRANS-
AXLE.CRANKSHAFT MAIN
BEARINGS
DESCRIPTION
Main bearings (Fig. 26) 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
five main bearings. Number three 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.
STANDARD PROCEDUREÐCRANKSHAFT MAIN
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.2 and 4
are interchangeable.
Upper and lower No.3 bearing halves are flanged
to carry the crankshaft thrust loads. They are NOT
interchangeable with any other bearing halves in the
engine (Fig. 27). Bearing shells are available in stan-
dard and the following undersizes: Never install an
undersize bearing that will reduce clearance below
specifications.
Fig. 25 Apply Sealant to Bearing Cap to Block Joint
1 - MOPAR SILICONE RUBBER ADHESIVE SEALANT NOZZLE
TIP
2 - SEALANT APPLIED
3 - CYLINDER BLOCK
4 - REAR MAIN BEARING CAP
Fig. 26 Main Bearing Orientation
DRENGINE - 5.9L 9 - 253
CRANKSHAFT (Continued)

(b) Arrange second compression ring 90É clock-
wise from the oil ring rail gap (Fig. 43).
VIBRATION DAMPER
REMOVAL
(1) Disconnect the battery negative cable.
(2) Remove the cooling system fan (Refer to 7 -
COOLING/ENGINE/FAN DRIVE VISCOUS
CLUTCH - REMOVAL).
(3) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(4) Remove vibration damper bolt and washer from
end of crankshaft.
(5) Position Special Tool 8513 Insert into the
crankshaft nose.(6) Install Special Tool 1026 Three Jaw Puller onto
the vibration damper (Fig. 44).
(7) Pull vibration damper off of the crankshaft.
INSTALLATION
CAUTION: Thoroughly remove any contaminants
from the crankshaft nose and the vibration damper
bore. Failure to do so can cause sever damage to
the crankshaft.
(1)
Position the vibration damper onto the crankshaft.
(2) Place installing tool, part of Puller Tool Set
C-3688 in position and press the vibration damper
onto the crankshaft (Fig. 45).
(3) Install the crankshaft bolt and washer. Tighten
the bolt to 244 N´m (180 ft. lbs.) torque.
(4) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(5)
Position the fan shroud and install the bolts.
Tighten the retainer bolts to 11 N´m (95 in. lbs.) torque.
(6) Install the cooling fan (Refer to 7 - COOLING/
ENGINE/FAN DRIVE VISCOUS CLUTCH -
INSTALLATION).
(7) Connect the battery negative cable.
Fig. 42 Compression Ring Chamfer Location (Typical)
1 - CHAMFER
2 - TOP COMPRESSION RING
3 - SECOND COMPRESSION RING
4 - PISTON
5 - CHAMFER
Fig. 43 Proper Ring Installation
1 - OIL RING SPACER GAP
2 - SECOND COMPRESSION RING GAP OIL RING RAIL GAP
(TOP)
3 - OIL RING RAIL GAP (BOTTOM)
4 - TOP COMPRESSION RING GAP
Fig. 44 Vibration Damper Removal
1 - SPECIAL TOOL 8513 INSERT
2 - SPECIAL TOOL 1026
Fig. 45 Vibration Damper Installation
1 - SPECIAL TOOL C-3688
DRENGINE - 5.9L 9 - 263
PISTON RINGS (Continued)

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 occur, the area of the sus-
pected 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 end seals.
(18) Remove the throttle body bolts and lift the
throttle body off the intake manifold (Fig. 68). Dis-
card the gasket.
(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 gasket surfaces using a suit-
able 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 removed, position new plenum gasket and
install plenum pan (Fig. 69).
(2) Tighten plenum pan mounting bolts as follows:
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 all bolts are at 9.5 N´m (84 in.
lbs.)
(3) 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. 71). The words MANIFOLD SIDE should be vis-
ible on the center of each flange gasket.
(4) 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. The sealant should be approxi-
mately 5 mm (0.2 in) in diameter and 15 mm (0.6 in.)
long.
Fig. 68 Throttle Body Assembly
1 - FUEL RAIL ASSEMBLY
2 - FUEL RAIL MOUNTING BOLTS
3 - FUEL RAIL CONNECTING HOSES
DRENGINE - 5.9L 9 - 275
INTAKE MANIFOLD (Continued)

equipped, the speed control and transmission kick-
down cables.
(16) Install the fuel lines (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE).
(17) Install the accessory drive bracket and A/C
compressor (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/A/C COMPRESSOR -
INSTALLATION).
(18) Install the generator and drive belt (Refer to 7
- COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION). Tighten generator mounting bolt
to 41 N´m (30 ft. lbs.) torque.
(19) Install the air cleaner.
(20) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(21) Connect the negative cable to the battery.
EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifolds (Fig. 73) 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) Remove the bolts and nuts attaching the
exhaust pipe to the engine exhaust manifold.
(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. 74).
(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. 74).
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. 72 Intake Manifold Bolt Tightening SequenceFig. 73 Exhaust ManifoldsÐV-8 Gas Engines Typical
1 - EXHAUST MANIFOLD (LEFT)
2 - BOLTS & WASHERS
3 - NUTS & WASHERS
4 - EXHAUST MANIFOLD (RIGHT)
5 - BOLTS & WASHERS
DRENGINE - 5.9L 9 - 277
INTAKE MANIFOLD (Continued)