Valve DODGE RAM 2001 Service Repair Manual

DESCRIPTION SPECIFICATION
valve closed 378 N @ 41.66 mm
(85 lbs. @ 1.64 in.)
valve open 890 N @ 30.89 mm
(200 lbs. @ 1.212 in.)
Number of Coils 6.5
Installed Height 41.66 mm
(1.64 in.)
Wire Diameter 4.50 mm
(0.177 in.)
HYDRAULIC TAPPETS
Body Diameter 22.949 ± 22.962 mm
(0.9035 ± 0.9040 in.)
Clearance (to bore) 0.0279 ± 0.0610 mm
(0.0011 ± 0.0024 in.)
Dry Lash 1.524 ± 5.334 mm
(0.060 ± 0.210 in.)
Push Rod Length 175.64 ± 176.15 mm
(6.915 ± 6.935 in.)
OIL PRESSURE
Curb Idle (Min.*) 41.4 kPa (6 psi)
@ 3000 rpm 207 ± 552 kPa
(30 ± 80 psi)
Oil Pressure Bypass
Valve
Setting 62 ± 103 kPa
(9 ± 15 psi)
Switch Actuating
Pressure34.5 ± 48.3 kPa
(5 ± 7 psi)
* If oil pressure is zero at curb idle, DO NOT RUN
ENGINE.
OIL PUMP
Clearance over Rotors
(Max.)0.0381 mm
(0.0015 in.)DESCRIPTION SPECIFICATION
Inner Rotor Thickness
(Min.)20.955 mm
(0.825 in.)
Outer Rotor Clearance
(Max.)0.3556 mm
(0.014 in.)
Outer Rotor Diameter
(Min.)62.7126 mm
(2.469 in.)
Outer Rotor Thickness
(Min.)20.955 mm
(0.825 in.)
Tip Clearance between
Rotors
(Max.) 0.2032 mm
(0.008 in.)
PISTONS
Clearance at Top of Skirt 0.013 ± 0.038 mm
(0.0005 ± 0.0015 in.)
Land Clearance (Diam.) 0.635 ± 1.016 mm
(0.025 ± 0.040 in.)
Piston Length 86.360 mm (3.40 in.)
Piston Ring Groove
Depth
Groove #1&2 4.572 ± 4.826 mm
(0.180 ± 0.190 in.)
Groove #3 3.810 ± 4.064 mm
(0.150 ± 0.160 in.)
Weight 592.6 ± 596.6 grams
(20.90 ± 21.04 oz.)
PISTON PIN
Clearance in Piston 0.00635 ± 0.01905 mm
(0.00025 ± 0.00075 in.)
Diameter 24.996 ± 25.001 mm
(0.9841 ± 0.9843 in.)
End Play NONE
Length 75.946 ± 76.454 mm
(2.990 ± 3.010 in.)
9 - 74 ENGINE 5.2LBR/BE
ENGINE 5.2L (Continued)

DESCRIPTION SPECIFICATION
PISTON RINGS
Ring Gap
Compression Rings 0.254 ± 0.508 mm
(0.010 ± 0.020 in.)
Oil Control (Steel Rails) 0.254 ± 1.270 mm
(0.010 ± 0.050 in.)
Ring Side Clearance
Compression Rings 0.038 ± 0.076 mm
(0.0015 ± 0.0030 in.)
Oil Ring (Steel Rails) 0.06 ± 0.21 mm
(0.002 ± 0.008 in.)
Ring Width
Compression rings 1.971 ± 1.989 mm
(0.0776 ± 0.0783 in.)
Oil Ring (Steel Rails) ±
Max.3.848 ± 3.975 mm
(0.1515 ± 0.1565 in.)
VALVE TIMING
Exhaust Valve
Closes (ATDC) 21É
Opens (BBDC) 60É
Duration 264É
Intake Valve
Closes (ATDC) 61É
Opens (BBDC) 10É
Duration 250É
Valve Overlap 31ÉOVERSIZE AND UNDERSIZE ENGINE
COMPONENT MARKINGS CHART
U/S-O/S Item Identification Identification
Location
U/S Rod/ R or M R-1-4
ect.Milled flat on
No.8
.0254
mmMain (indicating No.
1crankshaft
(0.001
in.)Journal and 4
connectingcounterweight.
rod journal)
and/or
M-2-3 ect.
(indicating No.
2
and 3 main
bearing
journal)
O/S HydraulicLDiamond-
shaped
.2032
mmTappets stamp top pad
-
(.008 in.) front of engine
and flat
ground
on outside
surface of
each
O/S tappet
bore.
O/S Valve X Milled pad
.127 mm Stems adjacent to
two
(.005 in.) tapped holes
(3/8 in.) on
each
end of
cylinder
head.
BR/BEENGINE 5.2L 9 - 75
ENGINE 5.2L (Continued)

SPECIAL TOOLS
5.2L ENGINE
Oil Pressure Gauge C-3292
Engine Support Fixture C-3487±A
Valve Spring Compressor MD-998772±A
Adaptor 6633
Adaptor 6716A
Valve Guide Sleeve C-3973
Dial Indicator C-3339
Puller C-3688
Puller 1026
Crankshaft Damper Removal Insert 8513
BR/BEENGINE 5.2L 9 - 77
ENGINE 5.2L (Continued)

CYLINDER HEAD
DESCRIPTIONÐCYLINDER HEAD
The cast iron cylinder heads (Fig. 4) are mounted
to the cylinder block using ten bolts. The spark plugs
are located in the peak of the wedge between the
valves.
DESCRIPTIONÐCYLINDER COVER GASKET
The cylinder head cover gasket (Fig. 5) is a steel-
backed silicone gasket, designed for long life usage.
OPERATIONÐCYLINDER HEAD
The cylinder head closes the combustion chamber
allowing the pistons to compress the air fuel mixture
to the correct ratio for ignition. The valves located in
the cylinder head open and close to either allow clean
air into the combustion chamber or to allow theexhaust gases out, depending on the stroke of the
engine.
OPERATION
The steel-backed silicone gasket is designed to seal
the cylinder head cover for long periods of time
through extensive heat and cold, without failure. The
gasket is designed to be reusable.
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET FAILURE
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
²Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
²Loss of engine power
²Engine misfiring
²Poor fuel economy
²Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
²Engine overheating
²Loss of coolant
²Excessive steam (white smoke) emitting from
exhaust
²Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test in this
section. An engine cylinder head gasket leaking
between adjacent cylinders will result in approxi-
mately a 50±70% reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
Fig. 4 Cylinder Head AssemblyÐV-8 Gas Engines
1 - EXHAUST VALVE
2 - SPARK PLUGS
3 - EXHAUST VALVES
4 - SPARK PLUGS
5 - EXHAUST VALVE
6 - INTAKE VALVES
7 - INTAKE VALVES
Fig. 5 Cylinder Head Cover Gasket V-8 Gas Engines
1 - CYLINDER HEAD COVER GASKET
BR/BEENGINE 5.2L 9 - 79

CAUTION: When tightening the rocker arm bolts,
make sure the piston in that cylinder is NOT at
TDC. Contact between the valves and piston could
occur.
(6) Install push rods and rocker arm assemblies in
their original position. Tighten the bolts to 28 N´m
(21 ft. lbs.) torque.
(7) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION) and throttle body assembly.
(8) Install exhaust manifolds (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
INSTALLATION).
(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) Install the air cleaner.
(22) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(23) Connect the negative cable to the battery.
(24) Start engine check for leaks.
CYLINDER HEAD COVER(S)
REMOVAL
NOTE: A steel backed silicon gasket is used with
the cylinder head cover (Fig. 7). 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.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
Both the intake and exhaust valves are made of
steel. The intake valve is 48.768 mm (1.92 inches) in
diameter and the exhaust valve is 41.148 mm (1.62
inches) in diameter and has a 2.032 mm (0.080 inch)
wafer interia welded to the tip for durability. These
valves are not splayed.
Fig. 7 Cylinder Head Cover Gasket
1 - CYLINDER HEAD COVER GASKET
BR/BEENGINE 5.2L 9 - 81
CYLINDER HEAD (Continued)

STANDARD PROCEDUREÐVALVES, GUIDES
AND SPRINGS
VALVE 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.
VALVE GUIDES
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. 8). 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. 9).
(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.
VALVE GUIDES
Service valves with oversize stems are available.
Refer to REAMER SIZES CHART
REAMER SIZES CHART
REAMER O/S VALVE GUIDE SIZE
0.076 mm 8.026 - 8.052 mm
(0.003 in.) (0.316 - 0.317 in.)
0.381 mm 8.331 - 8.357 mm
(0.015 in.) (0.328 - 0.329 in.)
(1) Slowly turn reamer by hand and clean guide
thoroughly before installing new valve.Ream the
valve guides from standard to 0.381 mm (0.015
in.). Use a two step procedure so the valve
guides are reamed true in relation to the valve
seat:
²Step 1ÐReam to 0.0763 mm (0.003 inch).
²Step 2ÐReam to 0.381 mm (0.015 inch).
Fig. 8 Positioning Valve with Tool C-3973
1 - VALVE
2 - SPACER TOOL
Fig. 9 Measuring Valve Guide Wear
1 - VALVE
2 - SPECIAL TOOL C-3339
9 - 82 ENGINE 5.2LBR/BE
INTAKE/EXHAUST VALVES & SEATS (Continued)

REFACING VALVES AND VALVE SEATS
The intake and exhaust valves have a 43-1/4É to
43-3/4É face angle and a 44-1/4É to 44-3/4É seat angle
(Fig. 10).
VALVE FACE AND VALVE SEAT ANGLE CHART
ITEM DESCRIPTION SPECIFICATION
ASEAT WIDTH
INTAKE 1.016 - 1.524 mm
(0.040 - 0.060 in.)
EXHAUST 1.524 - 2.032 mm
(0.060 - 0.080 in.)
BFACE ANGLE
(INT. AND EXT.) 43òÉ - 43ôÉ
CSEAT ANGLE
(INT. AND EXT.) 44òÉ - 44ôÉ
DCONTACT
SURFACE Ð
VALVES
Inspect the remaining margin after the valves are
refaced (Fig. 11). Valves with less than 1.190 mm
(0.047 in.) margin should be discarded.
VALVE SEATS
CAUTION: DO NOT un-shroud valves during valve
seat refacing (Fig. 12).
Fig. 10 Valve Face and Seat Angles
1 - CONTACT POINT
A,B,C and D Refer to VALVE FACE AND VALVE SEAT ANGLE
CHART
Fig. 11 Intake and Exhaust Valves
1 - MARGIN
2 - VALVE SPRING RETAINER LOCK GROOVE
3 - STEM
4-FACE
Fig. 12 Refacing Valve Seats
1-STONE
2 - PILOT
3 - VALVE SEAT
4 - SHROUD
BR/BEENGINE 5.2L 9 - 83
INTAKE/EXHAUST VALVES & SEATS (Continued)

(1) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-
ing stones. A true and complete surface must be
obtained.
(2) Measure the concentricity of valve seat using a
dial indicator. Total runout should not exceed 0.051
mm (0.002 in.) total indicator reading.
(3) Inspect the valve seat with Prussian blue, to
determine where the valve contacts the seat. To do
this, coat valve seat LIGHTLY with Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is trans-
ferred to the top edge of valve face, lower valve seat
with a 15É stone. If the blue is transferred to bottom
edge of valve face raise valve seat with a 60É stone.
(4) When seat is properly positioned the width of
intake seats should be 1.016-1.524 mm (0.040-0.060
in.). The width of the exhaust seats should be 1.524-
2.032 mm (0.060-0.080 in.).
VALVE SPRINGS
Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested. As an example the compression length of
the spring to be tested is 1-5/16 in.. Turn table of
Universal Valve Spring Tester Tool until surface is in
line with the 1-5/16 in. mark on the threaded stud.
Be sure the zero mark is to the front (Fig. 13). Place
spring over stud on the table and lift compressing
lever to set tone device. Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by 2. This will give the
spring load at test length. Fractional measurements
are indicated on the table for finer adjustments.
Refer to specifications to obtain specified height and
allowable tensions. Discard the springs that do not
meet specifications.
REMOVAL
(1) Remove the cylinder head (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(2) Compress valve springs using Valve Spring
Compressor Tool MD- 998772A and adapter 6716A.
(3) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(4) 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. 14). 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. 15).
(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.
Fig. 13 Testing Valve Spring for Compressed
Length
1 - TORQUE WRENCH
2 - VALVE SPRING TESTER
Fig. 14 Positioning Valve with Tool C-3973
1 - VALVE
2 - SPACER TOOL
9 - 84 ENGINE 5.2LBR/BE
INTAKE/EXHAUST VALVES & SEATS (Continued)

INSTALLATION
(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) Coat valve stems with lubrication oil and insert
them in cylinder head.
(5) If valves or seats are reground, check valve
stem height. If valve is too long, replace cylinder
head.
(6) Install new seals on all valve guides. Install
valve springs and valve retainers.
(7) Compress valve springs with Valve Spring
Compressor Tool MD-998772A and adapter 6716A,
install locks and release tool. If valves and/or seats
are ground, measure the installed height of springs.
Make sure the measurement is taken from bottom of
spring seat in cylinder 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 counterbore. This should bring spring
height back to normal 41.27 to 42.86 mm (1-5/8 to
1-11/16 inch).
(8) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
ROCKER ARM / ADJUSTER
ASSEMBLY
REMOVAL
(1) Remove cylinder head cover and gasket (Refer
to 9 - ENGINE/CYLINDER HEAD/CYLINDER
HEAD COVER(S) - REMOVAL).
(2) Remove the rocker arm bolts and pivots (Fig.
16). Place them on a bench in the same order as
removed.
(3) Remove the push rods and place them on a
bench in the same order as removed.
INSTALLATION
(1) Rotate the crankshaft until the ªV8º mark lines
up with the TDC mark on the timing chain case
cover. This mark is located 147É ATDC from the No.1
firing position.
(2) Install the push rods in the same order as
removed.
(3) Install rocker arm and pivot assemblies in the
same order as removed. Tighten the rocker arm bolts
to 28 N´m (21 ft. lbs.) torque.
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).
(4) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
Fig. 15 Measuring Valve Guide Wear
1 - VALVE
2 - SPECIAL TOOL C-3339
Fig. 16 Rocker Arms
1 - ROCKER ARMS
2 - CYLINDER HEAD
BR/BEENGINE 5.2L 9 - 85
INTAKE/EXHAUST VALVES & SEATS (Continued)

(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. 20).
(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 BEARINGS
(1) Install new camshaft bearings with Camshaft
Bearing Remover/Installer Tool C-3132-A by sliding
the new camshaft bearing shell over proper adapter.
(2) Position rear bearing in the tool. Install horse-
shoe lock and by reversing removal procedure, care-
fully drive bearing shell into place.
(3) Install remaining bearings in the same man-
ner. 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 holes
are 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 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. 21).
(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.
Fig. 20 Timing Chain Oil
1 - THRUST PLATE FRONT SIDE
2 - CHAIN OIL TAB
3 - THRUST PLATE REAR SIDE
Fig. 21 Camshaft Holding Tool C-3509 (Installed
Position)
1 - SPECIAL TOOL C-3509
2 - DRIVE GEAR
3 - DISTRIBUTOR LOCK BOLT
BR/BEENGINE 5.2L 9 - 87
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)