height DODGE RAM 2001 Service Workshop Manual

install locks and release tool. Tap the retainer with a
brass or heavy plastic hammer to ensure locks have
been seated.
(8) If valves and/or seats were ground, measure
the installed height of springs. Make sure the mea-
surement is taken from bottom of spring seat in cyl-
inder 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 coun-
terbore. Ensure this brings spring height back to nor-
mal, 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch).
(9) Install the cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
ROCKER ARM / ADJUSTER
ASSY
REMOVAL
(1) Disconnect spark plug wires by pulling the boot
straight out in line with plug.
(2) Remove cylinder head cover and gasket (Refer
to 9 - ENGINE/CYLINDER HEAD/CYLINDER
HEAD COVER(S) - REMOVAL).
(3) Remove the rocker arm bolts and the rocker
arm assembly (Fig. 26). Place rocker arm assemblies
on a bench in the same order as removed.
(4) Remove the push rods and place them on a
bench in the same order as removed.
INSTALLATION
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).
(1) Install the push rods in the same order as
removed.
(2) Install rocker arm assemblies in the same
order as removed. Tighten the rocker arm bolts to 28
N´m (21 ft. lbs.) torque.
(3) Install cylinder head cover and gasket (Refer to
9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(4) Connect spark plug wires.
ENGINE BLOCK
CLEANING
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leaking.
INSPECTION
Examine block for cracks or fractures.
The cylinder walls should be checked for out-of-
round and taper with Cylinder Bore Indicator Tool,
Special tool 6879 or equivalent. The cylinder block
should be bored and honed with new pistons and
rings fitted if:
²The cylinder bores show more than 0.127 mm
(0.005 inch) out-of-round.
²The cylinder bores show a taper of more than
0.254 mm (0.010 inch).
²The cylinder walls are badly scuffed or scored.
Boring and honing operation should be closely coor-
dinated with the fitting of pistons and rings so spec-
ified clearances may be maintained.
CAMSHAFT & BEARINGS (IN
BLOCK)
REMOVALÐCAMSHAFT BEARINGS
This procedure requires that the engine is removed
from the vehicle.
(1) With engine completely disassembled, drive out
rear cam bearing core hole plug.
NOTE: It is not advisable to attempt to replace cam-
shaft bearings unless special removal and installa-
tion tools are available, such as recommended tool
8544 Camshaft Bushing Remover Installer.
Fig. 26 Rocker Arm
1 - ROCKER ARMS
2 - ROCKER ARM PEDESTALS
3 - RETAINER
9 - 200 ENGINE 8.0LBR/BE
INTAKE/EXHAUST VALVES & SEATS (Continued)

(29)Remove the camshaft (Fig. 91) and thrust plate.
INSPECTION
Camshaft
(1)Inspect the valve lobes and bearing journals for
cracks, pitting, scoring, or generally excessive wear.
Replace any camshaft that exceeds the allowable limits.
(2)Measure the bearing journals and lobes (Fig. 92).
CAUTION: If Camshaft lobes are worn, requiring
camshaft replacement, it is necessary to replace the
tappets also. (Refer to 9 - ENGINE/ENGINE BLOCK/
SOLID LIFTERS - REMOVAL).
Camshaft Bushing/Bores
Camshaft bores No. 2±7do notuse a bushing.
(1) Inspect the camshaft bushing and bores for
signs of excessive wear.
(2) Measure the camshaft bushing and bores (Fig.
93) with a telescoping bore gauge and micrometer. If
out of specification, (Refer to 9 - ENGINE/ENGINE
BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) -
REMOVAL).
(3) Inspect the camshaft bushing oil hole for align-
ment with cylinder block (Fig. 94).
Fig. 92 Measuring
1 - VALVE LOBE
2 - CAMSHAFT JOURNAL
JOURNAL DIAMETER #1 54.028 mm (2.1270 in.) MIN.
JOURNAL DIAMETER #2 - 7 53.987 mm (2.1245 in.) MIN.
LOBE HEIGHT INTAKE 47.173 mm (1.857 in.) MIN.
LOBE HEIGHT EXHAUST 45.636 mm (1.796 in.) MIN.
Fig. 91 Camshaft Removal/Installation
Fig. 93 Measuring Camshaft Bushing and Bores
Fig. 94 Inspecting Oil Hole Alignment
1 - CAMSHAFT BUSHING
9 - 272 ENGINE 5.9L DIESELBR/BE
CAMSHAFT & BEARINGS (IN BLOCK) (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)

(5) Install new plastic tie strap (Fig. 28) to secure
sensor pigtail harness to side of engine block. Thread
tie strap through casting hole on cylinder block.
FUEL PUMP RELAY
DESCRIPTION
The 5±pin, 12±volt, fuel pump relay is located in
the Power Distribution Center (PDC). Refer to the
label on the PDC cover for relay location.
OPERATION
The Powertrain Control Module (PCM) energizes
the electric fuel pump through the fuel pump relay.
The fuel pump relay is energized by first applying
battery voltage to it when the ignition key is turned
ON, and then applying a ground signal to the relay
from the PCM.
Whenever the ignition key is turned ON, the elec-
tric fuel pump will operate. But, the PCM will shut-
down the ground circuit to the fuel pump relay in
approximately 1±3 seconds unless the engine is oper-
ating or the starter motor is engaged.
REMOVAL
The fuel pump relay is located in the Power Distri-
bution Center (PDC) (Fig. 31). Refer to label on PDC
cover for relay location.
(1) Remove PDC cover.
(2) Remove relay from PDC.
(3) Check condition of relay terminals and PDC
connector terminals for damage or corrosion. Repair
if necessary before installing relay.
(4) Check for pin height (pin height should be the
same for all terminals within the PDC connector).
Repair if necessary before installing relay.
INSTALLATION
The fuel pump relay is located in the Power Distri-
bution Center (PDC) (Fig. 31). Refer to label on PDC
cover for relay location.
(1) Install relay to PDC.
(2) Install cover to PDC.
IDLE AIR CONTROL MOTOR
DESCRIPTION
The IAC stepper motor is mounted to the throttle
body, and regulates the amount of air bypassing the
control of the throttle plate. As engine loads and
ambient temperatures change, engine rpm changes.
A pintle on the IAC stepper motor protrudes into a
passage in the throttle body, controlling air flow
through the passage. The IAC is controlled by the
Powertrain Control Module (PCM) to maintain the
target engine idle speed.
OPERATION
At idle, engine speed can be increased by retract-
ing the IAC motor pintle and allowing more air to
pass through the port, or it can be decreased by
restricting the passage with the pintle and diminish-
ing the amount of air bypassing the throttle plate.
The IAC is called a stepper motor because it is
moved (rotated) in steps, or increments. Opening the
IAC opens an air passage around the throttle blade
which increases RPM.
The PCM uses the IAC motor to control idle speed
(along with timing) and to reach a desired MAP dur-
ing decel (keep engine from stalling).
The IAC motor has 4 wires with 4 circuits. Two of
the wires are for 12 volts and ground to supply electri-
cal current to the motor windings to operate the step-
per motor in one direction. The other 2 wires are also
for 12 volts and ground to supply electrical current to
operate the stepper motor in the opposite direction.
To make the IAC go in the opposite direction, the
PCM just reverses polarity on both windings. If only
1 wire is open, the IAC can only be moved 1 step
(increment) in either direction. To keep the IAC
motor in position when no movement is needed, the
PCM will energize both windings at the same time.
This locks the IAC motor in place.
In the IAC motor system, the PCM will count
every step that the motor is moved. This allows the
PCM to determine the motor pintle position. If the
memory is cleared, the PCM no longer knows the
position of the pintle. So at the first key ON, the
PCM drives the IAC motor closed, regardless of
where it was before. This zeros the counter. From
this point the PCM will back out the IAC motor and
keep track of its position again.
Fig. 31 Power Distribution Center (PDC)
1 - POWER DISTRIBUTION CENTER (PDC)
BR/BEFUEL INJECTION - GASOLINE 14 - 41
CRANKSHAFT POSITION SENSOR (Continued)

CAUTION: Do not allow the ohmmeter to contact
terminals 85 or 86 during these tests. Damage to
ohmmeter may result.
(7) Attach the other jumper wire (12V +) to termi-
nal number 86. This will activate the relay. Continu-
ity should now be present between terminals number
87 and 30. Continuity should not be present between
terminals number 87A and 30.
(8) Disconnect jumper wires from relay and 12 Volt
power source.
(9) If continuity or resistance tests did not pass,
replace relay. If tests passed, refer to 8, Wiring Dia-
grams for (fuel system) relay wiring schematics and
for additional circuit information.
REMOVAL
The fuel heater relay is located in the Power Dis-
tribution Center (PDC) (Fig. 13). Refer to label under
PDC cover for relay location.
(1) Remove PDC cover.
(2) Remove relay from PDC.
(3) Check condition of relay terminals and PDC
connector terminals for damage or corrosion. Repair
if necessary before installing relay.
(4) Check for pin height (pin height should be the
same for all terminals within the PDC connector).
Repair if necessary before installing relay.
INSTALLATION
The fuel heater relay is located in the Power Dis-
tribution Center (PDC) (Fig. 13). Refer to label under
PDC cover for relay location.
(1) Install relay to PDC.
(2) Install cover to PDC.
FUEL INJECTION PUMP
DESCRIPTIONÐFUEL PUMP 245 H.P.
Although the fuel injection pump on the 245 horse-
power engine appears similar to other VP 44 injec-
tion pumps, there are internal differences that make
it unique. If pump replacement is necessary, be sure
to verify pump number. The pump number can be
found on the Fuel Injection Pump Data Plate (Fig.
14).
Fig. 13 Power Distribution Center (PDC) Location
1 - CLIP
2 - BATTERY
3 - TRAY
4 - NEGATIVE CABLE
5 - POSITIVE CABLE
6 - CLIP
7 - FENDER INNER SHIELD
8 - POWER DISTRIBUTION CENTER
Fig. 14 Fuel Injection Pump Data Plate Location
1 - PUMP DATA PLATE
BR/BEFUEL DELIVERY - DIESEL 14 - 65
FUEL HEATER RELAY (Continued)

(9) Remove the reverse idler shaft support bolt
(front bolt) (Fig. 19).
(10) Loosen rear reverse idler shaft bolt (rear bolt)
(Fig. 19).
(11) Remove reverse idler shaft support segment
by sliding it straight out of housing.
(12) Support geartrain and rear housing on Fix-
ture 6747 as follows:
(a) Adjust height of reverse idler pedestal rod
until the reverse idle shaft bottoms in Cup 8115.
(b) Position Adapters 6747-1A and 6747-2B on
Fixture 6747.
(c) Slide fixture tool onto input shaft, counter-
shaft and idler gear (Fig. 20).
(d) Stand geartrain and rear housing upright on
fixture (Fig. 21). Have helper hold fixture tool in
place while housing and geartrain is being rotated
into upright position.
Fig. 14 Shift Shaft Lever And Bushing Roll Pin
1 - PIN PUNCH
2 - BUSHING AND LEVER
3 - SHIFT SHAFT
Fig. 15 Shift Shaft
1 - SHIFT SHAFT
2 - 3-4 FORK
3 - SHAFT DETENT NOTCHES
Fig. 16 Shift Socket And Roll
1 - SHAFT BORE
2 - ROLL PIN
3 - SHIFT SOCKET
Fig. 17 Shift Shaft Lever And Bushing
1 - SHAFT LEVER AND BUSHING
2 - 3-4 FORK
Fig. 18 3-4 Shift Fork
1 - 3-4 FORK
2 - 1-2 AND 5TH-REVERSE FORK ARMS
3 - 3-4 SYNCHRO SLEEVE
21 - 8 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

(4) Install fourth gear synchro ring on input shaft
(Fig. 81).
(5) Adjust height of idler gear pedestal on assem-
bly fixture (Fig. 82). Start with a basic height of 18.4
cm (7-1/4 in.). Final adjustment can be made after
gear is positioned on pedestal.
Fig. 79 Fixture For Geartrain Build-up
1 - ADAPTER 6747-2B
2 - CUP 8115
3 - ADAPTER 6747-1A
4 - FIXTURE 6747
Fig. 80 Pilot Bearing And Input Shaft
1 - PILOT BEARING
2 - INPUT SHAFT
Fig. 81 Fourth Gear Synchro
1 - FOURTH GEAR SYNCHRO RING
2 - INPUT SHAFT
Fig. 82 Idler Pedestal Base Height
1 - REVERSE IDLER PEDESTAL
21 - 28 MANUAL - NV3500BR/BE
MANUAL - NV3500 (Continued)

(6) Install assembled output shaft and geartrain in
input shaft (Fig. 83). Carefully rotate output shaft
until the 3-4 synchro ring seats in synchro hub and
sleeve.
(7) Install Adapter 6747-2B on front bearing hub
of countershaft, if not previously done. The shoulder
goes toward the countershaft.
(8) Slide countershaft (and adapter) into fixture
slot. Verify countershaft and output shaft gears are
fully meshed with the mainshaft gears before pro-
ceeding (Fig. 84).(9) Check alignment of countershaft and output
shaft gear teeth. Gears may not align perfectly a dif-
ference in height of 1.57 to 3.18 mm (1/16 to 1/8 in.)
will probably exist. This difference will not interfere
with assembly. If difference is greater than this, the
countershaft adapter tool is probably upside down.
Remove countershaft, reverse adapter tool, reinstall
countershaft and check alignment again.
(10) Position reverse idler in support cup of assem-
bly fixture (Fig. 85). Verify idler gear is properly
meshed and aligned with shaft gear teeth and that
bolt holes are facing out from the geartrain. Adjust
pedestal up or down if necessary and verify short end
of idler shaft is facing up as shown.
Fig. 83 Output Shaft And Geartrain Installed In Input
1 - OUTPUT SHAFT AND GEARTRAIN
2 - INPUT SHAFT
3 - FIXTURE 6747
Fig. 84 Countershaft On Fixture Tool
1 - OUTPUT SHAFT AND GEARTRAIN
2 - COUNTERSHAFT (SLIDE INTO PLACE ON FIXTURE TOOL)
BR/BEMANUAL - NV3500 21 - 29
MANUAL - NV3500 (Continued)

EXTENSION/ADAPTER HOUSING
(1) Install extension housing bushing with
Installer 8156 and Handle C-4171, if necessary. The
oil feed hole must be at the 12 o'clock position when
installed.
(2) On 4X2 vehicles, install extension housing seal
with Installer 8154 and Handle C-4171, with the
weep hole at the bottom.
NOTE: Drain hole located in the dust boot portion
of the seal must face downward ( toward the
ground) when installed.
(3) On 4X4 vehicles, install adapter housing seal
with Installer C-3860-A and Handle C-4171.
(4) Install the crossover cam bushing into the
extension/adapter housing with Installer 8239 and
Handle C-4171.
(5) Clean the rear of the transmission case of all
sealer.
(6) Install reverse countershaft gear bearing race
onto the reverse countershaft gear bearing.
(7) Measure the distance from the back of the
bearing race to Gauge Bar 6311 (Fig. 94).(8) Measure thickness of the gauge bar and record
the total of the two measurements.
(9) Clean all the sealer from the extension/adapter
housing.
(10) Place Gauge Bar 6311 across the housing face.
Measure the distance from the top of the bar to the
bottom of the reverse countershaft bearing race bore
(Fig. 95).
(11) Subtract thickness of the gauge bar from the
measurement and record the result.
(12) The difference between the two measurements
is the end-play for the reverse countershaft gear
assembly.
(13) Install shims to achieve 0.15-0.25 mm (0.006-
0.010 in.) end-play for the reverse countershaft gear
assembly into the reverse countershaft bearing race
bore.
(14) Use Installer to install the reverse counter-
shaft bearing race into the extension/adapter hous-
ing.
(15) Install back-up lamp switch and a new gasket
into the extension/adapter housing. Tighten switch to
28 N´m (20 ft.lbs.).
(16) Install crossover cam into the extension/
adapter housing.
(17) Install bolt to hold the crossover cam to the
extension/adapter housing (Fig. 96).
Fig. 94 Measure Height of Reverse Countershaft
1 - MEASURE DISTANCE FROM RACE TO GAUGE BAR 6311
Fig. 95 Reverse Countershaft Gear Bearing Race
Bore
1 - GAUGE BAR 6311 TO BEARING RACE BORE
MEASUREMENT
21 - 124 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

WINDSHIELD
DESCRIPTION
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
URETHANE ADHESIVES ARE APPLIED AS A SYS-
TEM. USE GLASS CLEANER, GLASS PREP SOL-
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND
PINCH WELD (FENCE) PRIMER PROVIDED BY THE
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL
INTEGRITY COULD BE COMPROMISED.
DAIMLERCHRYSLER DOES NOT RECOMMEND
GLASS ADHESIVE BY BRAND. TECHNICIANS
SHOULD REVIEW PRODUCT LABELS AND TECHNI-
CAL DATA SHEETS, AND USE ONLY ADHESIVES
THAT THEIR MANUFACTURES WARRANT WILL
RESTORE A VEHICLE TO THE REQUIREMENTS OF
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE
THAT PRIMERS AND CLEANERS ARE COMPATIBLE
WITH THE PARTICULAR ADHESIVE USED.
BE SURE TO REFER TO THE URETHANE MANU-
FACTURER'S DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
OPERATION
The windshield is attached to the window frame
with urethane adhesive. The urethane adhesive is
applied cold and seals the surface area between the
window opening and the glass. The primer adheres
the urethane adhesive to the windshield.
It is difficult to salvage a windshield during the
removal operation. The windshield is part of the
structural support for the roof. The urethane bonding
used to secure the windshield to the fence is difficultto cut or clean from any surface. If the moldings are
set in urethane, it would also be unlikely they could
be salvaged. Before removing the windshield, check
the availability of the windshield and moldings from
the parts supplier.
REMOVAL
(1) Remove inside rear view mirror. (Refer to 23 -
BODY/INTERIOR/REAR VIEW MIRROR - REMOV-
AL).
(2) Remove cowl grill. (Refer to 23 - BODY/EXTE-
RIOR/COWL GRILLE - REMOVAL).
(3) With doors open, remove windshield molding
(Fig. 7). Pull outward on molding beginning at the
bottom of A-pillars using pliers.
(4) Cut urethane bonding from around windshield
using a suitable sharp cold knife (C-4849). A pneu-
matic cutting device can be used but is not recom-
mended (Fig. 8).
(5) Separate windshield from vehicle.
INSTALLATION
WARNING: Allow the urethane at least 24 hours to
cure before returning the vehicle to use.
CAUTION: Roll down the left and right front door
glass and open the rear glass slider (if available)
before installing windshield to avoid pressurizing
the passenger compartment if a door is slammed
before urethane is cured. Water leaks can result.
The windshield fence should be cleaned of most of
its old urethane bonding material. A small amount of
old urethane, approximately 1-2 mm in height,
Fig. 7 Windshield Moldings
1 - WINDSHIELD
2 - WINDSHIELD MOLDING
23 - 148 STATIONARY GLASSBR/BE