lock DODGE RAM 2001 Service Repair Manual

²If a new cylinder block and/or crankshaft is used,
the piston grading procedureMUST
be performed to
determine the proper piston grade for each cylinder.
(1) Install any of the original connecting rod and
piston assemblies into the No.1 cylinder. DO NOT
install the piston rings.
(2) Install the upper bearing shell in the connect-
ing rod with the tang of the bearing in the slot of the
connecting rod. The connecting rod bearing shell
must be installed in the original connecting rod and
cap. Use clean lubricating oil to coat the inside diam-
eter of the connecting rod bearing shell.
(3) Install the bearing shell in the connecting rod
cap with the tang of the bearing in the slot to the
cap. Use clean lubricating oil to coat the inside diam-
eter of the bearing shell.(4) The four digit number stamped on the connect-
ing rod and cap at the parting line must match and
be installed on the oil cooler side of the engine.
Install the connecting rod cap and cap screws.
Tighten the cap screws to 35 N´m (26 ft. lbs.) torque.
(5) Use a fine grit stone to remove any burrs from
the cylinder block head deck. Zero the dial indicator
to the cylinder block head deck.
(6) Move the dial indicator directly over the piston
pin to eliminate any side-to-side movement.
(7) Rotate the crankshaft to top dead center
(TDC). Rotate the crankshaft clockwise and counter-
clockwise to find the highest dial indicator reading.
Record the reading.
(8)
Remove the piston and connecting rod assembly
from the No.1 cylinder and install the assembly into the
No.2 cylinder. Repeat the procedure for every cylinder
using the same piston and connecting rod assembly.
(9)Determine the grade of the piston being used by
referring to the Piston Protrusion Chart below. Four
digits on top of the piston can be cross referenced to a
DaimlerChrysler part number for replacement (Fig.
126). If the number on the piston cannot be seen, mea-
sure from the top of the piston to the top of the piston
pin to see what grade piston is used (Fig. 127).
NOTE: NEVER INTERMIX PISTONS FROM ONE
ENGINE APPLICATION TO ANOTHER ENGINE
APPLICATION. SEVER DRIVEABILITY CONCERNS
MAY RESULT.
Fig. 124 Piston Ring Identification
Fig. 125 Connecting RodFig. 126 Piston Grading Number Location
BR/BEENGINE 5.9L DIESEL 9 - 283
PISTON & CONNECTING ROD (Continued)

INSTALLATION
(1) Lubricate the cylinder bores with clean engine
oil.
(2) Generously lubricate the rings and piston
skirts with clean engine oil.
(3) Compress the rings using a piston ring com-
pressor tool (Fig. 133). If using a strap-type ring com-
pressor, make sure the inside end of the strap does
not hook on a ring gap and break the ring.
(4) Bar the crankshaft so the rod journal for the
piston to be installed is at BDC (Bottom Dead Cen-
ter) - (Fig. 134).
(5) Be sure the mark you made on the piston and
the numbers on the rod and cap are oriented as illus-
trated.
(6) Position the piston and rod assembly into the
cylinder bore with the mark you made on the piston
towards the front of the cylinder block. In this posi-
tion the numbers on the connecting rod should be
facing the oil cooler side of the engine, and the rod
bolt holes toward the camshaft. Use care when you
install the piston and connecting rod so the cylinder
bore is not damaged.
(7) Push the piston into the bore until the top of
the piston is approximately 50 mm (2 inch) below thetop of the block. Carefully pull the connecting rod
onto the crankshaft journal.
(8) Use clean engine oil to lubricate the threads
and under the heads of the connecting rod bolts.
(9) The number stamped on the rod cap at the
parting line must match and be installed towards the
oil cooler side of the engine (Fig. 135).
(10) Install the rod cap and bolts to the connecting
rod. Tighten the connecting rod and bolt evenly in 3
steps.
²Tighten the bolts to 35 N´m (26 ft. lbs.) torque.
²Tighten the bolts to 70 N´m (51 ft. lbs.) torque.
²Tighten the bolts to 100 N´m (73 ft. lbs.) torque.
(11) The crankshaft must rotate freely. Check for
freedom of rotation as the caps are installed. If the
crankshaft does not rotate freely, check the installa-
tion of the rod bearing and the bearing size.
(12) Measure the side clearance between the con-
necting rod and the crankshaft (Fig. 136). DO NOT
measure the clearance between the cap and crank-
shaft.
Fig. 133 Piston Ring Compressor Tool
1 - PISTON RING COMPRESSOR TOOL
Fig. 134 Piston/Rod Assembly at BDC
Fig. 135 Correct Rod Cap Installation
Fig. 136 Side Clearance between Connecting
Rod/Crankshaft
1 - FEELER GAUGE
CONNECTING ROD SIDE CLEARANCE 0.1 - 0.33 mm ( .004 -
.013 inch)
BR/BEENGINE 5.9L DIESEL 9 - 287
PISTON & CONNECTING ROD (Continued)

FRONT MOUNT
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the viscous fan/drive assembly (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
(3) Raise vehicle on hoist.
(4) Support engine with a screw jack and wood
block.
(5) Loosen the thru-bolt and nut (Fig. 145).
(6) Passenger side mount: Remove the two (2)
transmission oil cooler bracket to engine mount bolts.
(7) Lift the engine SLIGHTLY and remove the four
(4) mount to block bolts.
(8) Remove the mount from the vehicle.
INSTALLATION
(1) With engine raised SLIGHTLY, position the
engine mount to the block. Install the bolts and
tighten to 149 N´m (110 ft. lbs.) torque.
(2) Install the thru-bolt into the engine mount.
(3) Lower the engine while guiding the mount and
thru-bolt into the frame mounted support cushion
brackets (Fig. 146).
(4) Install the thru-bolt nut and tighten the nut to
88 N´m (65 ft. lbs.) torque.
(5) Passenger side: Install the two (2) transmission
oil cooler bracket to mount bolts. Tighten the bolts to
47 N´m (35 ft. lbs.) torque.
(6) Remove lifting fixture.
(7) Lower the vehicle.
(8) Install the viscous fan/drive assembly (Refer to
7 - COOLING/ENGINE/RADIATOR FAN - INSTAL-
LATION).
(9) Connect the battery negative cables.
Fig. 145 Front Engine MountÐTypical
1 - MOUNT
2 - BOLT (4)
Fig. 146 Positioning Engine Front Mounts
1 - ENGINE SUPPORT BRACKET/CUSHION
2 - SUPPORT CUSHION BRACKET
9 - 290 ENGINE 5.9L DIESELBR/BE

LUBRICATION
DESCRIPTION
NOTE: Refer to (Fig. 148) and (Fig. 149) for circuit
illustrations.
A gear driven gerotor type oil pump is mounted
behind the front gear cover in the lower right portion
on the engine.
OPERATION
A gerotor style oil pump draws oil from the crank-
case through the suction tube and delivers it through
the block where it enters the oil cooler cover and
pressure regulator valve. When oil pressure exceeds
449 kPa (65 PSI), the valve opens exposing the dump
port, which routes excess oil back to the oil sump.
At the same time, oil is directed to a cast in pas-
sage in the oil cooler cover, leading to the oil cooler
element. As the oil travels through the element
plates, it is cooled by engine coolant traveling past
the outside of the plates. It is then routed to the oil
filter head and through a full flow oil filter. If a
plugged filter is encountered, the filter by-pass valve
opens, allowing unfiltered oil to lubricate the engine.
This condition can be avoided by frequent oil and fil-
ter changes, per the maintenance schedules found in
the owners manual. The by-pass valve is calibrated
to open when it sees a pressure drop of more than
344 kPa (50 psi) across the oil filter.The oil filter head then divides the oil between the
engine and the turbocharger. The turbocharger
receives filtered, cooled and pressurized oil through a
supply line from the filter head. The oil lubricates
the turbocharger and returns to the pan by way of a
drain tube connecting the bottom of the turbocharger
to a pressed in tube in the cylinder block.
Oil is then carried across the block to an angle
drilling which intersects the main oil rifle. The main
oil rifle runs the length of the block and delivers oil
to the crankshaft main journals and valve train. Oil
travels to the crankshaft through a series of transfer
drillings (one for each main bearing) and lubricates a
groove in the main bearing upper shell. From there
another drilling feeds the camshaft main journals.
The piston cooling nozzles are also supplied by the
main bearing upper shell. Crankshaft internal cross-
drillings supply oil to the connecting rod journals.
Another series of transfer drillings intersecting the
main oil rifle supply the valve train components. Oil
travels up the drilling, through a hole in the head
gasket, and through a drilling in the cylinder head
(one per cylinder), where it enters the rocker arm
pedestal and is divided between the intake and
exhaust rocker arm. Oil travels up and around the
rocker arm mounting bolt, and lubricates the rocker
shaft by cross drillings that intersect the mounting
bolt hole. Grooves at both ends of the rocker shaft
supply oil through the rocker arm where the oil trav-
els to the push rod and socket balls (Fig. 148) and
(Fig. 149).
9 - 292 ENGINE 5.9L DIESELBR/BE

²Milky discoloration indicates coolant dilution.
(4) Clean the area around the oil filter head.
Remove the filter (Refer to 9 - ENGINE/LUBRICA-
TION/OIL FILTER - REMOVAL).
(5) Install new oil filter (Refer to 9 - ENGINE/LU-
BRICATION/OIL FILTER - INSTALLATION).
(6) Clean the drain plug and the sealing surface of
the pan. Check the condition of the threads and seal-
ing surface on the oil pan and drain plug.
(7) Install the drain plug. Tighten the plug to 60
N´m (44 ft. lbs.) torque.
(8) Use only High-Quality Multi-Viscosity lubricat-
ing oil in the Cummins Turbo Diesel engine. Choose
the correct oil for the operating conditions (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
(9) Fill the engine with the correct grade of new oil
(Refer to LUBRICATION & MAINTENANCE/FLUID
CAPACITIES - SPECIFICATIONS).
(10) Start the engine and operate it at idle for sev-
eral minutes. Check for leaks at the filter and drain
plug.
(11) Stop engine. Wait several minutes to allow the
oil to drain back to the pan and check the level
again.
USED ENGINE OIL DISPOSAL Care should be
exercised when disposing of used engine oil after
it has been drained from a vehicle's engine.
OIL COOLER & LINES
CLEANING AND INSPECTION
Clean the sealing surfaces.
Apply 483 kPa (70 psi) air pressure to the element
to check for leaks. If the element leaks, replace the
element.
OIL FILTER
REMOVAL
(1) Clean the area around the oil filter head.
Remove the filter using a 90-95 mm filter wrench.
(2) Clean the gasket surface of the filter head. The
filter canister O-Ring seal can stick on the filter
head. Make sure it is removed.
INSTALLATION
(1) Fill the oil filter element with clean oil before
installation. Use the same type oil that will be used
in the engine.
(2) Apply a light film of lubricating oil to the seal-
ing surface before installing the filter.CAUTION: Mechanical over-tightening may distort
the threads or damage the filter element seal.
(3) Install the filter until it contacts the sealing
surface of the oil filter adapter. Tighten filter an
additional ó turn.
OIL PAN
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Remove transmission and transfer case (if
equipped).
(4) Remove flywheel.
(5) Disconnect starter cables from starter motor.
(6) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
and transmission adapter plate assembly.
WARNING: HOT OIL CAN CAUSE PERSONAL
INJURY.
(7) Drain the engine oil (Refer to 9 - ENGINE/LU-
BRICATION/OIL - STANDARD PROCEDURE).
(8) Install the oil pan drain plug with a new seal-
ing washer and tighten to 60 N´m (44 ft. lbs.) torque.
(9) Remove oil pan bolts, break the pan to block
seal, and lower pan slightly and remove oil suction
tube fasteners.
(10) Remove oil pan and suction tube (Fig. 151).
Fig. 151 Oil Pan, Suction Tube and Gasket
1 - GASKET
2 - SUCTION TUBE
3 - OIL PAN
9 - 296 ENGINE 5.9L DIESELBR/BE
OIL (Continued)

CLEANING
Remove all gasket material from the oil pan and
cylinder block sealing surfaces. Extra effort may be
required around T-joint areas. Clean oil pan and
flush suction tube with a suitable solvent.
INSPECTION
Inspect the oil pan, suction tube, and tube braces
for cracks and damage. Replace any defective compo-
nent. Inspect the oil drain plug and drain hole
threads. Inspect the oil pan sealing surface for
straightness. Repair any minor imperfections with a
ball-peen hammer. Do not attempt to repair an oil
pan by welding.
INSTALLATION
(1) Fill the T-joint between the pan rail/gear hous-
ing and pan rail/rear seal retainer with sealant. Use
MopartSilicone Rubber Adhesive Sealant or equiva-
lent.
(2) Place suction tube in oil pan and guide them
into place (Fig. 151). Using a new tube to oil pump
gasket, install and tighten the suction tube bolts by
hand. Starting with the oil pump inlet bolts, tighten
the bolts to 24 N´m (18 ft. lbs.) torque. Tighten the
remaining tube brace bolts to 24 N´m (18 ft. lbs.)
torque.
(3) Starting in the center and working outward,
tighten the oil pan bolts to 24 N´m (18 ft. lbs.)
torque.
(4) Install the flywheel housing assembly with the
starter motor attached and tighten bolts to 60 N´m
(44 ft. lbs.) torque.
(5) Connect starter motor cables.
(6) Install transmission and transfer case (if
equipped).
(7) Lower vehicle.
(8) Install battery negative cables.
(9) Fill the crankcase with new engine oil.
(10) Start engine and check for leaks. Stop engine,
check oil level, and adjust, if necessary.
OIL PRESSURE RELIEF VALVE
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the threaded plug, spring and plunger
(Fig. 152). Insert a finger or a seal pick to lift the
plunger from the bore.
NOTE: If the plunger is stuck in the bore, it will be
necessary to remove the filter head.
CLEANING
(1) Clean the regulator spring and plunger with a
suitable solvent and blow dry with compressed air. If
the plunger bore requires cleaning, it is necessary to
remove the oil filter head to avoid getting debris into
the engine.
INSPECTION
Inspect the plunger and plunger bore for cracks
and excessive wear. Polished surfaces are acceptable.
Verify that the plunger moves freely in the bore.
Check the spring for height and load limitations
(Fig. 153). Replace the spring if out of limits shown
in the figure.
Fig. 152 Oil Pressure Regulator
1 - OIL FILTER
2 - PLUG
3 - GASKET
4 - SPRING
5 - VALVE
Fig. 153 Oil Pressure Regulator Spring Check
BR/BEENGINE 5.9L DIESEL 9 - 297
OIL PAN (Continued)

INSTALLATION
(1) Install the plunger, spring, and plug as shown
in (Fig. 152). Tighten the plug to 80 N´m (60 ft. lbs.)
torque.
(2) Connect the battery negative cables.
(3) Start the engine and verify that it has oil pres-
sure.
OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
The 3±wire, solid-state oil pressure sensor is
installed into the oil pressure galley on the engine
block. It is located below and to the rear of the
Engine Control Module (ECM) (Fig. 154).
OPERATION
Operation of the oil pressure sensor on the
diesel engine is controlled by the Engine Con-
trol Module (ECM). The Powertrain Control
Module (PCM) does not have any control over
the sensor.The oil pressure sensor uses three circuits. They
are:
²A 5±volt power supply from the ECM
²A sensor ground through the ECM's sensor
return
²A signal to the ECM relating to engine oil pres-
sure
The oil pressure sensor has a 3±wire electrical
function very much like the Manifold Absolute Pres-
sure (MAP) sensor on the gasoline powered engine.
Meaning different pressures relate to different output
voltages.
A 5±volt supply is sent to the sensor from the ECM
to power up the sensor. The sensor returns a voltage
signal back to the ECM relating to engine oil pres-
sure. This signal is then transferred (bussed) to the
instrument panel on the CCD bus circuit to operate
the oil pressure gauge and the check gauges lamp.
Ground for the sensor is provided by the ECM
through a low-noise sensor return.
REMOVAL
(1) Disconnect the battery negative cables.
(2) Disconnect the oil pressure sensor connector
(Fig. 155).
(3) Using a suitable socket, remove the oil pres-
sure sensor from the block (counter-clockwise).
Fig. 154 Oil Pressure Sensor (Engine) Location
1 - ENGINE OIL PRESSURE SENSOR
2 - ELECTRIAL CONNECTOR
3 - ECM
Fig. 155 Oil Pressure Sensor Location
1 - ENGINE OIL PRESSURE SENSOR
2 - ELECTRIAL CONNECTOR
3 - ECM
9 - 298 ENGINE 5.9L DIESELBR/BE
OIL PRESSURE RELIEF VALVE (Continued)

INSTALLATION
(1) If the sensor is not being replaced, inspect the
o-ring (Fig. 156) and replace if necessary.
(2) Install the oil pressure sensor and tighten to 16
N´m (144 in. lbs.) torque.
(3) Connect the battery negative cables.
(4) Start engine and check for oil leaks at the sen-
sor.
OIL PUMP
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove fan/drive assembly (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL).
(3) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(4) Remove the fan support/hub assembly.
(5) Remove crankshaft damper (Fig. 157) (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(6) Remove the gear housing cover (Fig. 158)
(Refer to 9 - ENGINE/VALVE TIMING/GEAR HOUS-
ING COVER - REMOVAL).
(7) Remove the four mounting bolts and pull the
pump from the bore in the cylinder block (Fig. 159).
CLEANING
Clean all parts in solvent and dry with compressed
air. Clean the old sealer residue from the back of the
gear housing cover and front of the gear housing.
INSPECTION
Disassemble and inspect the oil pump as fol-
lows:
(1) Visually inspect the lube pump gears for chips,
cracks or excessive wear.
(2) Remove the back plate (Fig. 160).
(3) Mark TOP on the gerotor planetary using a felt
tip pen (Fig. 160).
(4) Remove the gerotor planetary (Fig. 160).
Inspect for excessive wear or damage. Inspect the
pump housing and gerotor drive for damaged and
excessive wear.
(5) Install the gerotor planetary in the original
position. The chamfer must be on the O.D. and down.
Fig. 156 Oil Pressure Sensor and
1 - ENGINE OIL PRESSURE SENSOR
2 - O-RING
Fig. 157 Crankshaft Damper Removal/Installation
1 - DAMPER
2 - BOLT
Fig. 158 Gear Housing and Cover
1 - GEAR HOUSING
2 - GEAR HOUSING COVER
BR/BEENGINE 5.9L DIESEL 9 - 299
OIL PRESSURE SENSOR/SWITCH (Continued)

(6) Measure the tip clearance (Fig. 161). Maximum
clearance is 0.1778 mm (0.007 inch). If the oil pump
is out of limits, replace the pump.
(7) Measure the clearance of the gerotor drive/
gerotor planetary to port plate (Fig. 162). Maximum
clearance is 0.127 mm (0.005 inch). If the oil pump is
out of limits, replace the pump.
(8) Measure the clearance of the gerotor planetary
to the body bore (Fig. 163). Maximum clearance is
0.381 mm (0.015 inch). If the oil pump is out of lim-
its, replace the pump.
(9) Measure the gears backlash (Fig. 164). The
limits of a used pump is 0.075- 0.85 mm (0.0296-
0.0335 inch). If the backlash is out of limits, replace
the oil pump.
(10) Install the back plate.
INSTALLATION
(1) Lubricate the pump with clean engine oil. Fill-
ing the pump with clean engine oil during installa-
tion will help to prime the pump at engine start up.
(2) Verify the idler gear pin is installed in the
locating bore in the cylinder block.
(3) Install the pump (Fig. 159). Tighten the oil
pump mounting bolts in two steps, in the sequence
shown in (Fig. 165).
²Step 1ÐTighten to 5 N´m (44 in. lbs.) torque.
²Step 2ÐTighten to 24 N´m (18 ft. lbs.) torque.
(4) The back plate on the pump seats against the
bottom of the bore in the cylinder block. When the
pump is correctly installed, the flange on the pump
will not touch the cylinder block.
(5) Measure the idler gear to pump drive gear
backlash and the idler gear to crankshaft gear back-
lash (Fig. 166). The backlash should be 0.75- 0.85mm (0.0296-0.0335 inch). If the backlash is out of
limits, replace the oil pump.
(6) If the adjoining gear moves when you measure
the backlash, the reading will be incorrect.
Fig. 159 Oil Pump Removal/Installation
1 - OIL PUMP
2 - BOLT (4)
Fig. 160 Gerotor Planetary and Gerotor
1 - OIL PUMP BACK PLATE
2 - GEROTOR
3 - GEROTOR PLANETARY
Fig. 161 Measuring Tip Clearance
1 - FEELER GAUGE
Fig. 162 Measuring Gerotor to Port Plate Clearance
1 - PORT PLATE
2 - GEROTOR
9 - 300 ENGINE 5.9L DIESELBR/BE
OIL PUMP (Continued)

(7) Apply a bead of MopartSilicone Rubber Adhe-
sive Sealant or equivalent to the gear housing cover
sealing surface.(8) Install the gear housing cover (Refer to 9 -
ENGINE/VALVE TIMING/GEAR HOUSING COVER
- INSTALLATION).
(9) Install the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(10) Install the fan support/hub assembly and
torque bolts to 24 N´m (18 ft. lbs.).
(11) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(12) Install the cooling fan (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION).
(13) Connect battery negative cables.
(14) Start engine and check for oil leaks.
INTAKE MANIFOLD
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the charge air cooler outlet tube from
the air inlet housing (Fig. 167).
(3) Remove the engine oil dipstick tube mounting
bolt (Fig. 167). Position dipstick tube to the side.
(4) Disconnect the air grid heater power cables at
the cable mounting studs (Fig. 168).
(5) Remove the four (4) air inlet housing mounting
bolts (Fig. 168) and remove the housing from top of
the heater elements.
(6) Remove the intake air grid heater from the
manifold (Fig. 169).
(7) Remove the high pressure fuel lines.(Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES
- REMOVAL).
(8) Remove the remaining intake manifold cover-
to-cylinder head bolts.
(9) Remove the intake manifold cover and gasket.
Keep the gasket material and any other material out
of the air intake.
(10) Clean the intake manifold cover and cylinder
head sealing surface.
Fig. 163 Measuring Gerotor Planetary to Body Bore
Clearance
1 - BODY BORE
2 - GEROTOR PLANETARY
Fig. 164 Measure Gear Backlash
1 - OIL PUMP DRIVE GEAR
2 - IDLER GEAR
3 - BACKLASH
4 - BACKLASH
Fig. 165 Oil Pump Mounting Bolt Torque Sequence
Fig. 166 Idler Gear to Pump Drive Gear and
Crankshaft Gear Backlash
BR/BEENGINE 5.9L DIESEL 9 - 301
OIL PUMP (Continued)