DODGE RAM 1999 Service Repair Manual

Fig. 15: Oil Pan Alignment Dowel Fabrication/Installation
Courtesy of Chrysler Corp.
OVERHAUL

CYLINDER HEAD
Cylinder Head
Check cylinder head warpage. Repair or replace cylinder head
if warpage exceeds specification. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS.
Valve Springs
1) Check valve spring free length, out-of-square and
pressure. Replace valve spring if not within specification. See VALVES
& VALVE SPRINGS table under ENGINE SPECIFICATIONS.
2) Measure valve spring installed height from bottom of
spring seat (cylinder head surface) to bottom of spring retainer. If
spacers are installed, measure from top of spacer.
3) If height exceeds 1.687" (42.86 mm), install a .066" (1.\
58
mm) thick spacer in cylinder head counterbore to obtain correct
installed spring height. See VALVES & VALVE SPRINGS table.
Valve Stem Oil Seals
Cup-type oil seals are used on all valves. Ensure oversize
valve stem oil seals are used when oversize valves are installed. When
installing valves, DO NOT overcompress valve springs, or damage to
valve stem oil seal may result.
NOTE: DO NOT ream valve guides from standard to maximum oversize in
one step. Ream valve guides to oversize in gradual steps so
guides are reamed true in relation to valve seat. After
reaming valve guides, valve seat runout must be checked.
Valve Guides
Check valve stem oil clearance. Ensure valve stem diameter is
within specification. Valve guide must be reamed for valve with
oversize valve stem if oil clearance exceeds specification. See
CYLINDER HEAD table under ENGINE SPECIFICATIONS. Valves are available
with stems of .015" (.38 mm) and .030" (.76 mm) oversize.
Valve Seat
Check valve seat width and runout. Grind valve seat if not
within specification. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS.
Valves
Ensure valve margin, head diameter and stem diameter are
within specification. See VALVES & VALVE SPRINGS table under ENGINE
SPECIFICATIONS. Valves are available with stems of .015" (.38 mm) and
.030" (.76 mm) oversize.
Valve Seat Correction Angles
Use a 15-degree stone to lower valve seat, and a 60-degree
stone to raise valve seat.
VALVE TRAIN
Rocker Arms & Pivots
Remove rocker arms and pivots. Inspect for wear. Replace as
necessary.
NOTE: Cylinder block must be marked to indicate oversize valve
lifters. See SPECIAL ENGINE MARKS.
Valve Lifters
Measure valve lifter diameter and bore diameter in cylinder

block. Determine oil clearance. Clearance must be within
specification. See VALVE LIFTERS table under ENGINE SPECIFICATIONS.
Cylinder block can be bored for oversize lifters.
CYLINDER BLOCK ASSEMBLY
Piston & Rod Assembly
Install piston with notch or groove on top of piston toward
front of engine (timing chain end) with larger chamfer of connecting
rod bore toward crankshaft journal fillet.
Fitting Pistons
1) Measure piston diameter at top of piston skirt at 90-
degree angle to piston pin axis. Measure cylinder bore diameter below
top surface of cylinder bore, middle of bore and bottom of cylinder
bore.
NOTE: Piston diameter and cylinder bore should be measured at room
temperature of 70
F (21C).
2) Ensure piston diameter and clearance are within
specification. See PISTONS, PINS & RINGS table under ENGINE
SPECIFICATIONS.
Piston Rings
1) Ensure ring end gap and side clearances are within
specification. See PISTONS, PINS & RINGS table under ENGINE
SPECIFICATIONS.
2) Position piston ring gaps in proper location. See Fig. 16.
Compression ring gaps must be staggered so they do not align with oil
ring rail gap. Ensure identification marks (drill point, letter "O",
an oval depression or the word TOP) on compression rings face upward.
Fig. 16: Positioning Piston Rings
Courtesy of Chrysler Corp.
Rod Bearings
1) Crankshaft is marked to indicate undersize rod bearings.
See SPECIAL ENGINE MARKS. When replacing connecting rod bearings,
ensure connecting rod is installed with larger chamfer of connecting
rod bore toward crankshaft journal fillet.
2) Apply light coat of engine oil to connecting rod bolt
threads before tightening nut to specification. See TORQUE
SPECIFICATIONS table. Ensure oil clearance and side play are within
specification. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table
under ENGINE SPECIFICATIONS.
Crankshaft & Main Bearings
1) Crankshaft is marked to indicate undersize main bearings.
See SPECIAL ENGINE MARKS. Main bearing cap location and direction of
installation should be marked before removal.

2) Ensure journal diameter, taper and out-of-round are within
specification. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table
under ENGINE SPECIFICATIONS. Upper main bearings contain oil holes,
while lower bearings installed in main bearing cap do not.
3) Apply light coat of engine oil to threads before
tightening bolt to specification. See TORQUE SPECIFICATIONS table.
Ensure oil clearance and end play are within specification. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table.
CAUTION: Crankshaft journal grinding should not exceed .012" (.30 mm)
under standard size. DO NOT grind thrust surfaces of No. 3
main bearing. Final paper or cloth polishing after regrind
must be done in same direction as engine rotation.
Thrust Bearing
Thrust bearing is located on No. 3 main bearing. Replace
thrust bearing if crankshaft end play is not within specification. See
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE
SPECIFICATIONS.
NOTE: Cylinder bore should be measured at room temperature of 70
F
(21C).
Cylinder Block
1) Check cylinder bore, out-of-round and taper. Measure
cylinder bore diameter below top surface of cylinder bore, middle of
bore and bottom of cylinder bore. Bore cylinder block if bore diameter
is not within specification. See CYLINDER BLOCK table under ENGINE
SPECIFICATIONS.
NOTE: Cylinder block is marked to indicate oversize valve lifters.
See SPECIAL ENGINE MARKS.
2) Check valve lifter bore diameter. Check for scoring. If
scoring exists or lifter bore diameter is not within specification,
ream cylinder block bore for next oversize valve lifter. See VALVE
LIFTERS table under ENGINE SPECIFICATIONS.
ENGINE OILING
ENGINE LUBRICATION SYSTEM
System has a rotor-type oil pump and full-flow oil filter.
Oil is forced by pump through a series of oil passages in engine to
provide lubrication to engine components. Oil is supplied to rocker
assembly through hollow push rods. Push rods are fed oil from lifters.
See Fig. 17 .
Crankcase Capacity
On 3.9L, oil capacity with oil filter is 4.0 qts. (3.8L). On
5.2L and 5.9L, oil capacity with oil filter is 5.0 qts. (4.7L).
Oil Pressure
Oil pressure is 6 psi (.4 kg/cm
) at idle and 30-80 psi (2.1-
5.6 kg/cm) at 3000 RPM with engine at normal operating temperature.

Fig. 17: Cross-Sectional View Of Engine Oil Circuit
Courtesy of Chrysler Corp.
OIL LINE PLUG
1) The oil line plug is located in vertical passage in rear
of block between oil-to-filter and oil-from-filter passages. See
Fig. 18 . Missing or improperly installed plug could cause erratic, low
or no oil pressure.
2) To check installation, remove oil sending unit and insert
wire down passage. Oil line plug should be 7.50-7.68 in. (190.0-195.2
mm) from machined surface of block. If plug is too high, use suitable
dowel to position properly. If plug is too low, remove oil pan, oil
pump and rear main bearing cap. Use suitable dowel to position
properly.
3) To remove for passage cleaning or plug replacement, drive
plug from oil sending unit hole out bottom of block. When installing

plug, coat outside diameter with Mopar Stud and Bearing Mount Adhesive
or equivalent. Plug should be 2.12-2.31 in. (54.0-57.7 mm) from bottom\
of block.
Fig. 18: Cross-Sectional View Of Oil Line Plug Location
Courtesy of Chrysler Corp.
OIL PUMP
Removal & Disassembly
1) Remove oil pan. See OIL PAN under REMOVAL & INSTALLATION.

Remove bolts and oil pump from rear main bearing cap.
2) Remove cotter pin. Drill a 1/8" (3.17 mm) hole into relie\
f
valve retainer cap and insert a self-tapping sheet metal screw into
cap. Clamp screw into vise. While supporting pump, remove retainer cap
by tapping pump body using soft-face hammer.
3) Discard retainer cap, and remove spring and relief valve.
Remove pump cover and discard oil seal ring. Remove inner rotor and
shaft and outer rotor. See Fig. 19.
Fig. 19: Exploded View Of Oil Pump Assembly
Courtesy of Chrysler Corp.
Inspection
1) Inspect components for damage. Using feeler gauge and
straightedge, check pump cover flatness. Measure thickness of inner
and outer rotors. Measure outer rotor outside diameter. Replace rotors
if not to specification. See OIL PUMP SPECIFICATIONS table.
2) Install outer rotor into pump body. Press outer rotor to
one side, and measure clearance between outer rotor and pump body.
Replace oil pump assembly if clearance exceeds specification. See OIL
PUMP SPECIFICATIONS table.
3) With outer rotor installed in pump body, install inner
rotor and shaft into pump body. Measure rotor tip clearance between
inner and outer rotors. Replace rotors if clearance exceeds
specification. See OIL PUMP SPECIFICATIONS table.
4) With rotors installed in pump body, place a straightedge
(between bolt holes) across face of pump body. Measure rotor end
clearance between rotors and straightedge. Replace oil pump assembly
if clearance exceeds specification. See OIL PUMP SPECIFICATIONS table.
5) Ensure relief valve slides freely in bore. Check free
length and tension of relief valve spring. Replace spring if not
within specification. See OIL PUMP SPECIFICATIONS table.

OIL PUMP SPECIFICATIONS








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Application Specification
Inner & Outer Rotor Thickness ................ .825" (20.96 mm) Min.\
Outer Rotor Diameter .......................... 2.47" (62.7 mm) Min.\
Outer Rotor-To-Pump Body Clearance ............. .014" (.36 mm) Max.\
Pump Cover Warpage ........................... .0015" (.038 mm) Max.\
Rotor End Clearance ................................. .004" (.10 mm)\
Rotor Tip Clearance ............................ .008" (.20 mm) Max.\
Spring Free Length ................................. 1.95" (49.5 mm)\
Spring Tension ......... 19.5-20.5 Lbs. @ 1.34" (8.8-9.3 kg @ 34 mm)\









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CAUTION: Ensure oil pump fully engages with distributor drive shaft
before tightening bolt. It may be necessary to slightly
rotate oil pump during installation to align with distributor
drive shaft.
Reassembly & Installation
To reassemble, reverse disassembly procedure. Install NEW
relief valve retainer cap and oil seal ring. Tighten pump cover bolts.
Fill rotor cavity with engine oil before installing. To install,
reverse removal procedure.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Axle Bracket-To-Bellhousing Bolt
Dakota 4WD & Durango 4WD ................................. 65 (88)\
Axle Shaft Nut
Dakota 4WD & Durango 4WD ............................... 180 (244)\
Axle Shaft-To-Differential Flange Bolt
Dakota 4WD & Durango 4WD ................................. 65 (88)\
Axle-To-Insulator Bolt
Dakota 4WD & Durango 4WD ................................ 75 (102)\
Camshaft Sprocket Bolt ..................................... 50 (68)\
Camshaft Thrust Plate Bolt ................................. 18 (24)\
Clutch Housing-To-Cylinder Block Bolt
Dakota
(1) ..................................................... 30 (41)
( 2) ..................................................... 50 (68)
Ram Pickup
( 1)
3/8" Bolt ............................................ 33 (45)\
7/16" Bolt ........................................... 50 (68)\
( 2) ........................................................ N/A
Connecting Rod Bolt ........................................ 45 (61)\
Crankshaft Pulley Bolt ..................................... 18 (24)\
Cylinder Head Bolt ( 3)
Step 1 ................................................... 50 (68)\
Step 2 ................................................. 105 (142)\
Step 3 (Verify Torque) ................................. 105 (142\
)
Differential Pinion Nose Bracket-To-Adapter Bolt
Dakota 4WD & Durango 4WD ................................. 65 (88)\
Differential Pinion Nose Bracket-To-Bellhousing Bolt
Dakota 4WD & Durango 4WD ................................. 65 (88)\
Engine Mount Bracket-To-Frame Rail Bolt
Dakota 2WD & Durango 2WD ................................. 30 (41)\

Engine Mount Through-Bolt
Dakota 2WD & Durango 2WD ................................. 50 (68)\
Dakota 4WD, Durango 4WD & Ram Pickup .................... 75 (102)\
Grand Cherokee ............................................. 60 (81)\
Engine Mount-To-Cylinder Block Bolt
Dakota & Durango ......................................... 30 (41)\
Ram Pickup ............................................... 60 (81)\
Ram Van/Wagon & Grand Cherokee ............................. 65 (88)\
Engine Mount-To-Frame Bracket Bolt/Nut
Ram Pickup & Ram Van/Wagon .............................. 75 (102)\
Exhaust Manifold Bolt & Nut
Durango .................................................. 18 (24)\
All Others ................................................. 25 (34)\
Flywheel/Flexplate-To-Crankshaft Bolt ...................... 55 (75)\
Front Cover Bolt ........................................... 30 (41)\
Heat Shield Bolts .......................................... 30 (41)\
Main Bearing Cap Bolt ..................................... 85 (115)\
Oil Drain Plug ............................................. 25 (34)\
Oil Filter Adapter Stud .................................... 50 (68)\
Oil Pan Bolt ............................................... 18 (24)\
Oil Pump Bolt .............................................. 30 (41)\
Rocker Arm Bolt ............................................ 21 (28)\
Shift Motor Bolt
Dakota 4WD & Durango 4WD ................................. 65 (88)\
Spark Plug ................................................. 30 (41)\
Starter Bolts .............................................. 50 (68)\
Throttle Body Bolt ......................................... 17 (23)\
Transfer Case Yoke Bolt
Dakota 4WD & Durango 4WD ................................. 20 (27)\
Vibration Damper Bolt .................................... 135 (183)\
Water Pump Bolt ............................................ 30 (41)\
INCH Lbs. (N.m)
Intake Manifold Bolt ( 4)
Step 1 .................................................. 24 (2.7)\
Step 2 .................................................. 48 (5.4)\
Step 3 .................................................. 84 (9.5)\
Step 4 (Verify Torque All Bolts) ........................ 84 (9.5\
)
Intake Manifold Plenum Pan Bolt
Step 1 .................................................. 24 (2.7)\
Step 2 .................................................. 48 (5.4)\
Step 3 .................................................. 84 (9.5)\
Step 4 (Verify Torque) .................................. 84 (9.5\
)
Oil Pump Cover Bolt ........................................ 97 (11)\
Valve Cover Bolts .......................................... 95 (11)\
( 1) - Bolts through clutch housing into cylinder block.
( 2) - Bolts through cylinder block into clutch housing.
( 3) - Tighten bolts in sequence. See 7.
( 4) - Tighten bolts in sequence. See 5 and 6.









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ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS (3.9L)








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Application Specification
Displacement .................................... 239 Cu. In. (3.9L)\
Bore ............................................... 3.91" (99.3 mm)\
Stroke ............................................. 3.31" (84.1 mm)\

Compression Ratio ............................................ 9.1:1
Fuel System .................................................... PFI









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GENERAL SPECIFICATIONS (5.2L)








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Application Specification
Displacement .................................... 318 Cu. In. (5.2L)\
Bore ............................................... 3.91" (99.3 mm)\
Stroke ............................................. 3.31" (84.1 mm)\
Compression Ratio ............................................ 9.1:1
Fuel System .................................................... PFI









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GENERAL SPECIFICATIONS (5.9L)








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Application Specification
Displacement .................................... 360 Cu. In. (5.9L)\
Bore .............................................. 4.00" (101.6 mm)\
Stroke ............................................. 3.58" (90.9 mm)\
Compression Ratio ............................................ 9.1:1
Fuel System .................................................... PFI









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CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS








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Application In. (mm)\
Crankshaft End Play
Standard ..................................... .002-.007 (.05-.18)\
Wear Limit ............................................ .010 (.25)\
Main Bearings
Journal Diameter
3.9L & 5.2L ....................... 2.4995-2.5005 (63.487-63.513)\
5.9L .............................. 2.8095-2.8105 (71.361-71.387)\
Journal Out-Of-Round .................................. .001 (.03)\
Journal Taper ......................................... .001 (.03)\
Oil Clearance
Journal No. 1
Standard .............................. .0005-.0015 (.013-.038)\
Wear Limit ....................................... .0015 (.038)\
All Others
Standard .............................. .0005-.0020 (.013-.051)\
Wear Limit ....................................... .0025 (.064)\
Connecting Rod Bearings
Journal Diameter ..................... 2.124-2.125 (53.950-53.975)\
Journal Out-Of-Round .................................. .001 (.03)\
Journal Taper ......................................... .001 (.03)\
Oil Clearance
Standard ................................ .0005-.0022 (.013-.056)\
Wear Limit ......................................... .0025 (.064)\
Side Play .................................... .006-.014 (.15-.36)\









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PISTONS, PINS & RINGS








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Application In. (mm)\
Piston Clearance ........................... .0005-.0015 (.013-.038)\
Pins
Diameter