engine DODGE RAM 2001 Service Repair Manual

DIAGNOSIS AND TESTINGÐREAR SEAL AREA
LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak:
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, distributor seal,
camshaft bore cup plugs, oil galley pipe plugs, oil
filter runoff, and main bearing cap to cylinder
block mating surfaces.
(4) If no leaks are detected, pressurized the crank-
case as outlined in (Refer to 9 - ENGINE/LUBRICA-
TION - DIAGNOSIS AND TESTING)
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks or
scratches. The crankshaft seal flange is specially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled. Refer to the service DiagnosisÐMechani-
cal, under the Oil Leak row, for components
inspections on possible causes and corrections.
(7) After the oil leak root cause and appropriate
corrective action have been identified, (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - REMOVAL), for proper replacement
procedures.
STANDARD PROCEDUREÐCYLINDER BORE
HONING
Before honing, stuff plenty of clean shop towels
under the bores and over the crankshaft to keep
abrasive materials from entering the crankshaft
area.
(1) Used carefully, the Cylinder Bore Sizing Hone
C-823, equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round, as well as removing light
scuffing, scoring and scratches. Usually, a few strokes
will clean up a bore and maintain the required lim-
its.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done if
the cylinder bore is straight and round. Use a cylin-
der surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). about 20-60
strokes, depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Using honing
oil C-3501-3880, or a light honing oil, available from
major oil distributors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits, or kerosene.
(3) Honing should be done by moving the hone up
and down fast enough to get a crosshatch pattern.
The hone marks should INTERSECT at 50É to 60É
for proper seating of rings (Fig. 3).
Fig. 3 Cylinder Bore Crosshatch Pattern
1 - CROSSHATCH PATTERN
2 - INTERSECT ANGLE
9 - 10 ENGINE 3.9LBR/BE
ENGINE 3.9L (Continued)

(4) A controlled hone motor speed between 200 and
300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 50É to 60É
angle. Faster up and down strokes increase the cross-
hatch angle.
(5) After honing, it is necessary that the block be
cleaned to remove all traces of abrasive. Use a brush
to wash parts with a solution of hot water and deter-
gent. Dry parts thoroughly. Use a clean, white, lint-
free cloth to check that the bore is clean. Oil the
bores after cleaning to prevent rusting.
STANDARD PROCEDUREÐHYDROSTATIC
LOCK
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock
(regardless of what caused the problem), follow the
steps below.
(1) Perform the Fuel Pressure Release Procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(2) Disconnect the negative cable(s) from the bat-
tery.
(3) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(4) Place a shop towel around the spark plugs to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the spark plugs.
(5) With all spark plugs removed, rotate the crank-
shaft using a breaker bar and socket.
(6) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
(7) Be sure all fluid has been removed from the
cylinders.
(8) Repair engine or components as necessary to
prevent this problem from occurring again.
(9) Squirt a small amount of engine oil into the
cylinders to lubricate the walls. This will prevent
damage on restart.
(10) Install new spark plugs. Tighten the spark
plugs to 41 N´m (30 ft. lbs.) torque.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N´m (25 ft. lbs.) torque.
(13) Install a new oil filter.
(14) Fill engine crankcase with the specified
amount and grade of oil. (Refer to LUBRICATION &
MAINTENANCE - SPECIFICATIONS).
(15) Connect the negative cable(s) to the battery.
(16) Start the engine and check for any leaks.
STANDARD PROCEDUREÐREPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repaired. Essen-
tially, this repair consists of:
²Drilling out worn or damaged threads.
²Tapping the hole with a special Heli-Coil Tap, or
equivalent.
²Installing an insert into the tapped hole to bring
the hole back to its original thread size.
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. Always
inspect 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
BR/BEENGINE 3.9L 9 - 11
ENGINE 3.9L (Continued)

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-
vent corrosion. MopartGasket Sealant is available in
a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assembling parts using a form-in-place gasket
requires care but it's easier then using precut gas-
kets.
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
MopartGasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the upper crossmember and top core
support.
(4) Remove the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
REMOVAL).(5) Discharge the air conditioning system, if
equipped (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove the A/C compressor with the lines
attached. Set aside.
(8) If equipped, remove the condenser (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - REMOVAL).
(9) Remove the washer bottle.
(10) Remove the fan and fan shroud (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(11) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(12) Remove the generator with the wire connec-
tions (Refer to 8 - ELECTRICAL/CHARGING/GEN-
ERATOR - REMOVAL).
(13) Remove the air cleaner box.
(14) Disconnect the throttle linkage.
(15) Remove throttle body (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/THROTTLE BODY -
REMOVAL).
(16) Remove the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL).
(17) Remove the distributor cap and wiring.
(18) Disconnect the heater hoses.
(19) Disconnect the power steering hoses, if
equipped.
(20) Perform the Fuel System Pressure release
procedure (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY - STANDARD PROCEDURE).Disconnect
the fuel supply line (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/QUICK CONNECT FITTING -
STANDARD PROCEDURE).
(21) On Manual Transmission vehicles, remove the
shift lever.
(22) Raise and support the vehicle on a hoist.
(23) Remove the drain plug and drain the engine
oil.
(24) Remove engine front mount through-bolt nuts.
(25)Automatic TransmissionRemove the trans-
mission cooler line brackets from oil pan.
(26) Disconnect exhaust pipe at manifold.
(27) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).
(28)Manual TransmissionRemove the transmis-
sion.(Refer to 21 - TRANSMISSION/TRANSAXLE/
MANUAL - REMOVAL).
(29) Lower the vehicle.
CAUTION: DO NOT lift the engine by the intake
manifold.
(30) Install an engine lifting fixture.
9 - 12 ENGINE 3.9LBR/BE
ENGINE 3.9L (Continued)

(31) Remove engine from vehicle and install
engine assembly on a repair stand.
INSTALLATION
(1) Remove engine from the repair stand and posi-
tion in the engine compartment. Position the
through-bolt into the support cushion brackets.
(2) Install an engine support fixture.
(3) Raise and support the vehicle on a hoist.
(4)Manual TransmissionInstall the transmis-
sion (Refer to 21 - TRANSMISSION/TRANSAXLE/
MANUAL - INSTALLATION).
(5) Install the starter and connect the starter
wires (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(6) Install exhaust pipe to manifold.
(7)Automatic TransmissionInstall the trans-
mission cooler line brackets on oil pan.
(8) Install engine front mount through-bolt nuts.
Tighten the nuts.
(9) Install the drain plug and tighten to 34 N´m
(25 ft. lbs.) torque.
(10) Lower the vehicle.
(11) Remove engine-lifting fixture.
(12) On Manual Transmission vehicles, install the
shift lever.
(13) Connect the fuel supply line (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/QUICK CON-
NECT FITTING - STANDARD PROCEDURE).
(14) Connect the power steering hoses, if equipped.
(15) Connect the heater hoses.
(16) Install the distributor cap and wiring.
(17) Install the intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).(18) Using a new gasket, install throttle body
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE BODY - INSTALLATION).
(19) Connect the throttle linkage.
(20) Install the air cleaner box.
(21) Install the generator and wire connections
(Refer to 8 - ELECTRICAL/STARTING/STARTER
MOTOR - INSTALLATION).
(22) Install radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - INSTALLATION).
(23) Install the fan and fan shroud (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
(24) Install the washer bottle.
(25) If equipped, install the condenser (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
A/C CONDENSER - INSTALLATION).
(26) Install the A/C compressor with the lines
attached.
(27) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(28) Evacuate and charge the air conditioning sys-
tem, if equipped (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE).
(29) Install the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS COOLER -
INSTALLATION).
(30) Install the upper crossmember and top core
support.
(31) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(32) Connect the negative cable to the battery.
(33) Start engine and check for leaks.
BR/BEENGINE 3.9L 9 - 13
ENGINE 3.9L (Continued)

SPECIFICATIONS
3.9L ENGINE
GENERAL DESCRIPTION
DESCRIPTION SPECIFICATION
Engine Type 90É V-6 OHV
Bore and Stroke 99.3 x 84.0 mm
(3.91 x 3.31 in.)
Displacement 3.9L (238 c.i.)
Compression Ratio 9.1:1
Firing Order 1±6±5±4±3±2
Cylinder Compression 689.5 kPa
Pressure (Min.) (100 psi)
CAMSHAFT
Bearing Diameter (Inside)
No. 1 50.800 - 50.825 mm
(2.000 - 2.001 in.)
No. 2 50.394 - 50.825 mm
(1.984 - 1.985 in.)
No. 3 49.606 - 49.632 mm
(1.953 - 1.954 in.)
No. 4 39.688 - 39.713 mm
(1.5265 - 1.5653 in.)
Journal Diameter
No. 1 50.749 - 50.775 mm
(1.998 - 1.999 in.)
No. 2 50.343 - 50.368 mm
(1.982 - 1.983 in.)
No. 3 49.555 - 49.581 mm
(1.951 - 1.952 in.)
No. 4 39.637 - 39.662 mm
(1.5605 - 1.5615 in.)
Bearing to Journal
Clearance
Standard 0.0254 - 0.0762 mm
(0.001 - 0.003 in.)
Max Allowable 0.127 mm
(0.005 in.)
DESCRIPTION SPECIFICATION
End Play 0.051 - 0.254 mm
(0.002 - 0.010 in.)
CONNECTING RODS
Piston Pin Bore Diameter 24.940 - 24.978 mm
(0.9819 - 0.9834 in.)
Side Clearance
(Two Rods) 0.152 - 0.356 mm
(0.006 - 0.014 in.)
Total Weight 762 grams
(25.61 oz.)
CRANKSHAFT
Rod Journal Diameter 53.950 - 53.975 mm
(2.124 - 2.125 in.)
Rod Journal Out of
Round
(Max) 0.0254 mm
(0.001 in.)
Rod Journal Taper
(Max) 0.0254 mm
(0.001 in.)
Rod Journal Bearing
Clearance0.013 - 0.056 mm
(0.0005 - 0.0022 in.)
Rod Journal Service Limit 0.08 mm
(0.003 in.)
Main Journal Diameter 63.487 - 63.513 mm
(2.4995 - 2.5005 in.)
Main Journal Out of
Round
(Max) 0.0254 mm
(0.001 in.)
Main Journal Taper
(Max) 0.0254 mm
(0.001 in.)
9 - 14 ENGINE 3.9LBR/BE
ENGINE 3.9L (Continued)

DESCRIPTION SPECIFICATION
Main Journal Beraing
Clearance
No. 1 0.013 - 0.038 mm
(0.0005 - 0.0015 in.)
No.2-40.013 - 0.051 mm
(0.0005 - 0.0020 in.)
Service Limit 0.064 mm
(0.0025 in.)
End Play 0.051 - 0.178 mm
(0.002 - 0.007 in.)
End Play Service Limit 0.254 mm
(0.010 in.)
CYLINDER BLOCK
Cylinder Bore Diameter 99.308 - 99.371 mm
(3.9098 - 3.9122 in.)
Cylinder Bore Out of
Round and
taper
(Max) 0.025 mm
(0.001 in.)
Lifter Bore Diameter 22.99 - 23.01 mm
(0.9501 - 0.9059 in.)
Distributor Drive Bushing
to
Bore Interference (Press
Fit)0.0127 - 0.3556 mm
(0.0005 - 0.0140 in.)
Distributor Shaft to
Bushing
Clearance 0.0178 - 0.0686 mm
(0.0007 - 0.0027 in.)
CYLINDER HEAD and VALVES
Valve Seat Angle 44.25É - 44.75É
Valve Seat Runout
(Max) 0.0762 mm
(0.003 in.)
Valve Seat Width (Finish)
Intake 1.016 - 1.542 mmDESCRIPTION SPECIFICATION
(0.040 - 0.060 in.)
Exhaust 1.524 - 2.032 mm
(0.040 - 0.060 in.)
Valve Face Angle 43.25É - 43.75É
Valve Head Diameter
Intake 48.666 mm
(1.916 in.)
Exhaust 41.250 mm
(1.624 in.)
Valve Length (Overall)
Intake 124.28 - 125.92 mm
(4.893 - 4.918 in.)
Exhaust 124.64 - 125.27 mm
(4.907 - 4.932 in.)
Valve Lift (@ Zero Lash) 10.973 mm
(0.432 in.)
Valve Stem Diameter 7.899 - 7.925 mm
(0.311 - 0.312 in.)
Valve Guide Bore
Diameter7.950 - 7.976 mm
(0.313 - 0.314 in.)
Valve Stem to Guide
Clearance0.0254 - 0.0762 mm
(0.001 - 0.003 in.)
Valve Stem to Guide
Clearance
Service Limit (Rocking
Method)0.4318 mm
(0.017 in.)
VALVE SPRINGS
Free Length 49.962 mm
(1.967 in.)
Spring Tension
Valve Closed 378 N @ 41.66 mm
(85 lbs. @ 1.64 in.)
Valve Open 890 N @ 30.89 mm
(200 lbs. @ 1.212 in.)
BR/BEENGINE 3.9L 9 - 15
ENGINE 3.9L (Continued)

DESCRIPTION SPECIFICATION
Number of Coils 6.8
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 in Block 0.0279 - 0.0610 mm
(0.0011 - 0.210 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)
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) 0.1016 mm
(0.004 in.)
Cover Out of Flat
(Max) 0.0381 mm
(0.0015 in.)
Inner Rotor Thickness
(Min) 20.955 mm
(0.825 in.)DESCRIPTION SPECIFICATION
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 0.0127 - 0.0381 mm
(0.0005 - 0.0015 in.)
Land Clearance
(Diameter)0.635 - 1.016 mm
(0.025 - 0.040 in.)
Piston Length 86.360 mm
(3.40 in.)
Ring Groove Depth
#1 & 2 4.572 - 4.826 mm
(0.180 - 0.190 in.)
#3 3.810 - 4.064 mm
(0.150 - 0.160 in.)
Weight 592.6 - 596.6 grams
(20.90 - 21.04 oz.)
PISTON PINS
Clearance in Piston 0.0064 - 0.0191 mm
(0.00025 - 0.00075 in.)
Clearance in Rod
(Interference)0.0178 - 0.0356 mm
(0.0007 - 0.0014 in.)
Diameter 24.996 - 25.001 mm
(0.9841 - 0.9843 in.)
9 - 16 ENGINE 3.9LBR/BE
ENGINE 3.9L (Continued)

DESCRIPTION SPECIFICATION
End Play None
Length 75.946 - 76.454 mm
(2.990 - 3.010 in.)
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 Control (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 Control (Steel Rails) 3.848 - 3.975 mm
(0.1515 - 0.1565 in.)
VALVE TIMING
Exhaust Valve
Closes 16É (ATDC)
Opens 52É (BBDC)
Duration 248É
Intake Valve
Closes 50É (ABDC)
Opens 10É (BTDC)
Duration 240É
Valve Overlap 26ÉOVERSIZE AND UNDERSIZE ENGINE
COMPONENT MARKINGS CHART
OS-US Item Identification Location of
Identification
U/S Crankshaft R or M M-2-3
ect.Milled flat on
.0254
MM(indicating No.
2&No. eight
(.001
IN.)3 main
bearingcrankshaft
journal) and/or counterweight.
R-1-4 ect.
(indicating No.
1&
4 connecting
rod
journal)
O/S TappetsL3/89
.2032
mmdiamound
(.008 in.) -shaped
stamp Top
pad
Ð Front of
engine and
flat
ground on
outside
surface
of each O/S
tappet bore.
O/S Valve
StemsX Milled pad
.127 mm adjacent to
two
(0.005
in.)3/89tapped
holes on
each
end of
cylinder
head.
BR/BEENGINE 3.9L 9 - 17
ENGINE 3.9L (Continued)

TORQUE
TORQUE CHART 3.9L ENGINE
DESCRIPTION N´m In. Ft.
Lbs. Lbs.
Camshaft SprocketÐBolt 68 Ð 50
Camshaft Thrust
PlateÐBolts24 210 Ð
Timing Chain Case
CoverÐ41 Ð 30
Bolts
Connecting Rod
CapÐBolts61 Ð 45
Main Bearing CapÐBolts 115 Ð 85
Crankshaft PulleyÐBolts 24 210 Ð
Cylinder HeadÐBolts
Step 1 68 Ð 50
Step 2 143 Ð 105
Cylinder Head CoverÐ
Bolts11 95 Ð
Engine Support Bracket 41 Ð 30
to Block (4wd)ÐBolts
Exhaust Manifold to
Cylinder34 Ð 25
HeadÐbolts/nuts
FlywheelÐBolts 75 Ð 55
Front InsulatorÐthrough
Bolts95 Ð 70
Front Insulator to
Support
Bracket (4wd)
ÐStud Nut 41 Ð 30
ÐThrough Bolt/Nut 102 Ð 75
Front Insulator to BlockÐ 95 Ð 70
Bolts (2wd)
GeneratorÐMounting
Bolt41 Ð 30
Intake ManifoldÐBolts Refer to Procedure
Oil PanÐBolts 24 215 Ð
Oil PanÐDrain Plug 34 Ð 25
Oil PumpÐMounting
Bolts41 Ð 30
Oil Pump CoverÐBolts 11 95 Ð
Rear Insulator to
BracketÐ68 Ð 50
DESCRIPTION N´m In. Ft.
Lbs. Lbs.
Through-Bolt (2WD)
Rear Insulator to
Crossmember41 Ð 30
Support BracketÐNut
(2WD)
Rear Insulator to 68 Ð 50
CrossmemberÐNuts
(4WD)
Rear Insulator to
Transmission68 Ð 50
Ð Bolts (4WD)
Rear Insulator BracketÐ
Bolts68 Ð 50
(4WD Automatic)
Rear Support Bracket to 41 Ð 30
Crossmember FlangeÐ
Nuts
Rear Support Plate to
Transfer41 Ð 30
CaseÐBolts
Rocker ArmÐBolts 28 Ð 21
Spark Plugs 41 Ð 30
Starter MotorÐMounting
Bolts68 Ð 50
Thermostat HousingÐ
Bolts25 225 Ð
Throttle BodyÐBolts 23 200 Ð
Torque Converter Drive
PlateÐ31 270 Ð
Bolts
Transfer Case to
Insulator204 Ð 150
Mounting PlateÐNuts
Transmission Support
Bracket68 Ð 50
ÐBolts (2WD)
Vibration DamperÐBolt 183 Ð 135
Water Pump to Timing
Chain41 Ð 30
Case CoverÐ Bolts
9 - 18 ENGINE 3.9LBR/BE
ENGINE 3.9L (Continued)

SPECIAL TOOLS
ENGINEÐ3.9L
Oil Pressure Gauge C-3292
Engine Support Fixture C-3487±A
Valve Spring Compressor MD-998772±A
Adapter 6633
Adapter 6716A
Valve Guide Sleeve C-3973
Dial Indicator C-3339
Puller C-3688
Front Oil Seal Installer 6635
Camshaft Holder C-3509
BR/BEENGINE 3.9L 9 - 19
ENGINE 3.9L (Continued)