engine oil DODGE RAM 2003 Service Repair Manual

Measure thickness and diameter of OUTER rotor.
If outer rotor thickness measures 20.9 mm (0.825
inch) or less or if the diameter is 62.7 mm (2.469
inches) or less, replace outer rotor (Fig. 61).
If inner rotor measures 20.9 mm (0.825 inch) or
less, replace inner rotor and shaft assembly (Fig. 62).
Slide outer rotor into pump body. Press rotor to the
side with your fingers and measure clearance
between rotor and pump body (Fig. 63). If clearance
is 0.356 mm (0.014 inch) or more, replace oil pump
assembly.
Install inner rotor and shaft into pump body. If
clearance between inner and outer rotors is 0.203
mm (0.008 inch) or more, replace shaft and both
rotors (Fig. 64).
Place a straightedge across the face of the pump,
between bolt holes. If a feeler gauge of 0.102 mm
(0.004 inch) or more can be inserted between rotors
and the straightedge, replace pump assembly (Fig.
65).
Inspect oil pressure relief valve plunger for scoring
and free operation in its bore. Small marks may be
removed with 400-grit wet or dry sandpaper.
Fig. 61 Measuring Outer Rotor Thickness
Fig. 62 Measuring Inner Rotor Thickness
Fig. 63 Measuring Outer Rotor Clearance in Housing
1 - PUMP BODY
2 - OUTER ROTOR
3 - FEELER GAUGE
Fig. 64 Measuring Clearance Between Rotors
1 - OUTER ROTOR
2 - FEELER GAUGE
3 - INNER ROTOR
Fig. 65 Measuring Clearance Over Rotors
1 - STRAIGHT EDGE
2 - FEELER GAUGE
DRENGINE - 5.9L 9 - 273
OIL PUMP (Continued)

The relief valve spring has a free length of approx-
imately 49.5 mm (1.95 inches). The spring should
test between 19.5 and 20.5 pounds when compressed
to 34 mm (1-11/32 inches). Replace spring that fails
to meet these specifications (Fig. 66).
If oil pressure was low and pump is within specifi-
cations, inspect for worn engine bearings or other
reasons for oil pressure loss.
ASSEMBLY
(1) Install pump rotors and shaft, using new parts
as required.
(2) Position the oil pump cover onto the pump
body. Tighten cover bolts to 11 N´m (95 in. lbs.)
torque.
(3) Install the relief valve and spring. Insert the
cotter pin.
(4) Tap on a new retainer cap.
(5) Prime oil pump before installation by filling
rotor cavity with engine oil.
INSTALLATION
(1) Install oil pump. During installation slowly
rotate pump body to ensure driveshaft-to-pump rotor
shaft engagement.
(2) Hold the oil pump base flush against mating
surface on No.5 main bearing cap. Finger tighten
pump attaching bolts. Tighten attaching bolts to 41
N´m (30 ft. lbs.) torque.
(3) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
INTAKE MANIFOLD
DESCRIPTION
The aluminum intake manifold (Fig. 67) is a single
plane design with equal length runners and uses a
separate plenum, therefore the manifold does have a
plenum gasket. It also uses separate flange gaskets
and front and rear cross-over gaskets. Extreme care
must be used when sealing the gaskets to ensure
that excess sealant does not enter the intake runners
causing a restriction. Whenever the intake manifold
is removed inspect the plenum pan for evidence of
excess oil buildup, this condition indicates that the
plenum pan gasket is leaking.
OPERATION
The intake manifold, meters and delivers air to the
combustion chambers allowing the fuel delivered by
the fuel injectors to ignite, thus producing power.
DIAGNOSIS AND TESTINGÐINTAKE
MANIFOLD LEAKAGE
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
Fig. 66 Proper Installation of Retainer Cap
1 - RETAINER CAP
2 - CHAMFER
3 - COTTER KEY
Fig. 67 Intake Manifold and Throttle BodyÐV-8 Gas
Engines Typical
1 - FUEL RAIL ASSEMBLY
2 - FUEL RAIL MOUNTING BOLTS
3 - FUEL RAIL CONNECTING HOSES
9 - 274 ENGINE - 5.9LDR
OIL PUMP (Continued)

WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS, OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water at the suspected
leak area.
(3) If a change in RPMs occur, the area of the sus-
pected leak has been found.
(4) Repair as required.
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(3) Remove the A/C compressor (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - REMOVAL).
(4) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(5) Remove the accessory drive bracket.
(6) Remove the air cleaner.
(7) Perform the Fuel System Pressure release pro-
cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV-
ERY - STANDARD PROCEDURE). Disconnect the
fuel lines (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE).
(8) Disconnect the accelerator linkage (Refer to 14
- FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - REMOVAL) and if so equipped,
the speed control and transmission kickdown cables.
(9) Remove the return spring.
(10) Remove the distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect the heat indicator sending unit
wire.
(13) Disconnect the heater hoses and bypass hose.
(14) Remove the closed crankcase ventilation and
evaporation control systems.
(15) Remove intake manifold bolts.
(16) Lift the intake manifold and throttle body out
of the engine compartment as an assembly.
(17) Remove and discard the flange side gaskets
and the front and rear end seals.
(18) Remove the throttle body bolts and lift the
throttle body off the intake manifold (Fig. 68). Dis-
card the gasket.
(19) If required, remove the plenum pan and gas-
ket. Discard gasket.
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.Clean cylinder block gasket surfaces using a suit-
able solvent.
The plenum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.
INSTALLATION
(1) If removed, position new plenum gasket and
install plenum pan (Fig. 69).
(2) Tighten plenum pan mounting bolts as follows:
²Step 1. Tighten bolts to 5.4 N´m (48 in. lbs.)
²Step 2. Tighten bolts to 9.5 N´m (84 in. lbs.)
²Step 3. Check all bolts are at 9.5 N´m (84 in.
lbs.)
(3) Install the flange gaskets. Ensure that the ver-
tical port alignment tab is resting on the deck face of
the block. Also the horizontal alignment tabs must be
in position with the mating cylinder head gasket tabs
(Fig. 71). The words MANIFOLD SIDE should be vis-
ible on the center of each flange gasket.
(4) Apply MopartGEN II Silicone Rubber Adhe-
sive Sealant, or equivalent, to the four corner joints.
An excessive amount of sealant is not required to
ensure a leak proof seal. However, an excessive
amount of sealant may reduce the effectiveness of
the flange gasket. The sealant should be approxi-
mately 5 mm (0.2 in) in diameter and 15 mm (0.6 in.)
long.
Fig. 68 Throttle Body Assembly
1 - FUEL RAIL ASSEMBLY
2 - FUEL RAIL MOUNTING BOLTS
3 - FUEL RAIL CONNECTING HOSES
DRENGINE - 5.9L 9 - 275
INTAKE MANIFOLD (Continued)

(5)Install the front and rear end seals (Fig. 70) Make
sure the molded dowel pins on the end seals fully enter the
corresponding holes in the cylinder block.
(6)Carefully lower intake manifold into position on
the cylinder block and cylinder heads. After intake man-
ifold is in place, inspect to make sure seals are in place.
(7) Using a new gasket, install the throttle body
onto the intake manifold. Tighten the bolts to 23 N´m
(200 in. lbs.) torque.(8) Install the intake manifold bolts and tighten as
follows (Fig. 72):
²Step 1. Tighten bolts 1 through 4 to 8 N´m (72
in. lbs.) Tighten in alternating steps 1.4 N´m (12 in.
lbs.) at a time
²Step 2. Tighten bolts 5 through 12 to 8 N´m (72
in. lbs.)
²Step 3. Check all bolts are torqued to 8 N´m (72
in. lbs.)
²Step 4. Tighten all bolts in sequence to 16 N´m
(12 ft. lbs.)
²Step 5. Check all bolts are torqued to 16 N´m
(12 ft. lbs.)
(9) Install closed crankcase ventilation and evapo-
ration control systems.
(10) Connect the coil wires.
(11) Connect the heat indicator sending unit wire.
(12) Connect the heater hoses and bypass hose.
(13) Install distributor cap and wires.
(14) Hook up the return spring.
(15) Connect the accelerator linkage (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/THROTTLE
CONTROL CABLE - INSTALLATION) and if so
Fig. 69 Plenum Pan Bolt Tightening Sequence
Fig. 70 Front and Rear End Seals
1 - FRONT CROSS-OVER GASKET
2 - REAR CROSS-OVER GASKET
Fig. 71 Intake Manifold Flange Gasket Alignment
1 - FLANGE GASKET
2 - ALIGNMENT TABS
3 - CYLINDER HEAD GASKET
9 - 276 ENGINE - 5.9LDR
INTAKE MANIFOLD (Continued)

(5) Assemble exhaust pipe to manifold and secure
with bolts, nuts and retainers. Tighten the bolts and
nuts to 34 N´m (25 ft. lbs.) torque.
(6) Lower the vehicle.
(7) Connect the negative cable to the battery.
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Remove water pump (Refer to 7 - COOLING/
ENGINE/WATER PUMP - REMOVAL).
(3) Remove power steering pump (Refer to 19 -
STEERING/PUMP - REMOVAL).
(4) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(5) Loosen oil pan bolts and remove the front bolt
at each side.
(6) Remove the cover bolts.
(7) Remove chain case cover and gasket using
extreme caution to avoid damaging oil pan gasket.
INSTALLATION
(1) Be sure mating surfaces of chain case cover
and cylinder block are clean and free from burrs.
(2) The water pump mounting surface must be
cleaned.
(3) Using a new cover gasket, carefully install
chain case cover to avoid damaging oil pan gasket.
Use a small amount of MopartSilicone Rubber Adhe-
sive Sealant, or equivalent, at the joint between tim-
ing chain cover gasket and the oil pan gasket. Finger
tighten the timing chain cover bolts at this time.NOTE: Special Tool 6635 must be used to align the
front cover and seal with the crankshaft.
(4) Position the special tool 6635 onto the crank-
shaft (Fig. 75).
(5) Tighten chain case cover bolts to 41 N´m (30
ft.lbs.) torque. Tighten oil pan bolts to 24 N´m (215
in. lbs.) torque.
(6) Remove special tool 6635.
(7)
Inspect the seal flange on the vibration damper.
(8) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(9) Install water pump and housing assembly
using new gaskets (Refer to 7 - COOLING/ENGINE/
WATER PUMP - INSTALLATION).
(10) Install power steering pump (Refer to 19 -
STEERING/PUMP - INSTALLATION).
(11) Install the serpentine belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(12) Install the cooling system fan (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
(13) Position the fan shroud and install the bolts.
Tighten the bolts to 11 N´m (95 in. lbs.) torque.
(14) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(15) Connect the negative cable to the battery.
(16) Start engine check for leaks.
Fig. 74 Engine Exhaust Manifold Installation - 5.9L
Engines
1 - EXHAUST MANIFOLD (LEFT)
2 - BOLTS & WASHERS
3 - NUTS & WASHERS
4 - EXHAUST MANIFOLD (RIGHT)
5 - BOLTS & WASHERS
Fig. 75 Position Special Tool 6635 onto Crankshaft
1 - SPECIAL TOOL 6635
2 - OIL SEAL
3 - TIMING CHAIN COVER
9 - 278 ENGINE - 5.9LDR
EXHAUST MANIFOLD (Continued)

CRANKSHAFT OIL SEAL - FRONT
REMOVAL............................323
INSTALLATION........................324
CRANKSHAFT OIL SEAL - REAR
REMOVAL............................325
INSTALLATION........................325
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL............................326
INSTALLATION........................326
SOLID LIFTERS/TAPPETS
REMOVAL............................327
CLEANING...........................328
INSPECTION.........................328
INSTALLATION........................328
PISTON & CONNECTING ROD
DESCRIPTION........................329
STANDARD PROCEDURE - HEAD GASKET
SELECTION.........................330
REMOVAL............................330
CLEANINGÐPISTON AND CONNECTING
ROD ..............................331
INSPECTION
INSPECTIONÐPISTONS...............331
INSPECTIONÐCONNECTING ROD.......332
INSTALLATION........................332
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING............................333
VIBRATION DAMPER
REMOVAL............................335
INSPECTION.........................335
INSTALLATION........................335
FRONT MOUNT
REMOVAL............................335
INSTALLATION........................335
REAR MOUNT
REMOVAL............................337
INSTALLATION........................337
LUBRICATION
DESCRIPTION........................337
OPERATION..........................337
DIAGNOSIS AND TESTINGÐENGINE OIL
PRESSURE.........................338
OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL
LEVEL.............................341STANDARD PROCEDURE - ENGINE OIL
SERVICE...........................341
OIL COOLER & LINES
CLEANING
CLEANING AND INSPECTION...........342
OIL FILTER
REMOVAL............................342
INSTALLATION........................342
OIL PAN
REMOVAL............................342
CLEANING...........................342
INSPECTION.........................342
INSTALLATION........................342
OIL PRESSURE RELIEF VALVE
REMOVAL............................343
CLEANING...........................343
INSPECTION.........................343
INSTALLATION........................343
OIL PRESSURE SENSOR/SWITCH
REMOVAL............................343
INSTALLATION........................343
OIL PUMP
REMOVAL............................343
CLEANING...........................344
INSPECTION.........................344
INSTALLATION........................344
INTAKE MANIFOLD
REMOVAL............................345
CLEANING...........................346
INSPECTION.........................346
INSTALLATION........................346
EXHAUST MANIFOLD
REMOVAL............................347
CLEANING...........................347
INSPECTION.........................347
INSTALLATION........................347
VALVE TIMING
STANDARD PROCEDURE - TIMING
VERIFICATION.......................348
GEAR HOUSING
REMOVAL............................348
INSTALLATION........................349
GEAR HOUSING COVER
REMOVAL............................349
INSTALLATION........................350
DRENGINE 5.9L DIESEL 9 - 281

ENGINE 5.9L DIESEL
DESCRIPTION
The cylinder block is constructed of cast iron. The
casting is a skirted design which incorporates longi-
tudal ribs for superior strength and noise reduction.
The block incorporates metric straight thread o-ring
fittings at lubrication oil access points. The engine
(Fig. 1) is manufactured with the cylinders being a
non-sleeved type cylinder. However, one approved
service method is to bore out the cylinders and add
cylinder sleeves to the cylinder block.
The cylinders are numbered front to rear (Fig. 2); 1
to 6. The firing order is 1±5±3±6±2±4.
Fig. 1 CumminsT24-Valve Turbo-Diesel Engine
Fig. 2 Cylinder Numbering
9 - 282 ENGINE 5.9L DIESELDR

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐENGINE DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTION
LUBRICATING OIL
PRESSURE LOW1. Low oil level. 1. (a) Check and fill with clean engine oil.
(b) Check for a severe external oil leak that
could reduce the pressure.
2. Oil viscosity thin, diluted or wrong
specification.2. (a) Verify the correct engine oil is being
used. (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
2. (b) Look for reduced viscosity from fuel
dilution.
3. Improperly operating pressure
switch/gauge.3. Verify the pressure switch is functioning
correctly. If not, replace switch/gauge.
4. Relief valve stuck open. 4. Check/replace valve.
6. If cooler was replaced, shipping
plugs may have been left in cooler6. Check/remove shipping plugs.
7. Worn oil pump. 7. Check and replace oil pump.
8. Suction tube loose or seal leaking. 8. Check and replace seal.
9. Loose main bearing cap. 9. Check and install new bearing. Tighten
cap to proper torque.
10. Worn bearings or wrong bearings
installed.10. Inspect and replace connecting rod or
main bearings. Check and replace directed
piston cooling nozzles.
11. Directed piston cooling nozzles
under piston, bad fit into main
carrier.11. Check directed piston cooling nozzles
position.
12. Loose oil rifle plug with saddle-jet
style nozzles12.Tighten oil rifle plug.
13. Loose directed piston cooling
nozzle.13. Tighten directed piston cooling nozzle.
14. Both J-jet and saddle jet style
cooling nozzle installed.14. Install correct style jet.
LUBRICATING OIL
PRESSURE TOO HIGH1. Pressure switch/gauge not
operating properly.1. Verify pressure switch is functioning
correctly. If not, replace switch/gauge.
2. Engine running too cold. 2. Refer to Coolant Temperature Below
Normal (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
3. Oil viscosity too thick. 3. Make sure the correct oil is being used.
(Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
4. Oil pressure relief valve stuck
closed or binding4. Check and replace valve.
DRENGINE 5.9L DIESEL 9 - 283
ENGINE 5.9L DIESEL (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
LUBRICATING OIL LOSS 1. External leaks. 1. Visually inspect for oil leaks. Repair as
required.
2. Crankcase being overfilled. 2. Verify that the correct dipstick is being
used.
3. Incorrect oil specification or
viscosity.3. (a) Make sure the correct oil is being
used (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
(b) Look for reduced viscosity from dilution
with fuel.
(c) Review/reduce oil change intervals.
4. Oil cooler leak 4. Check and replace the oil cooler.
5. High blow-by forcing oil out the
breather.5. Check the breather tube area for signs of
oil loss. Perform the required repairs.
6. Turbocharger leaking oil to the air
intake.6. Inspect the air ducts for evidence of oil
transfer. Repair as required.
COMPRESSION KNOCKS 1. Air in the fuel system. 1. Identify location of air leak and repair. Do
not bleed high pressure fuel system.
2. Poor quality fuel or water/gasoline
contaminated fuel.2. Verify by operating from a temporary
tank with good fuel. Clean and flush the
fuel tank. Replace fuel/water separator filter.
3. Engine overloaded. 3. Verify the engine load rating is not being
exceeded.
4. Improperly operating injectors. 5. Check and replace misfiring/inoperative
injectors.
EXCESSIVE VIBRATION 1. Loose or broken engine mounts. 1. Replace engine mounts.
2. Damaged fan or improperly
operating accessories.2. Check and replace the vibrating
components.
3. Improperly operating vibration
damper3. Inspect/replace vibration damper.
4. Improperly operating electronically
controlled viscous fan drive.4. Inspect/replace fan drive.
5. Worn or damaged generator
bearing.5. Check/replace generator.
6. Flywheel housing misaligned. 6. Check/correct flywheel alignment.
7. Loose or broken power
component.7. Inspect the crankshaft and rods for
damage that causes an unbalance
condition. Repair/replace as required.
8. Worn or unbalanced driveline
components.8. Check/repair driveline components.
EXCESSIVE ENGINE
NOISES1. Drive belt squeal, insufficient
tension or abnormally high loading.1. Check the automatic tensioner and
inspect the drive belt. Make sure water
pump, tensioner pulley, fan hub, generator
and power steering pump turn freely.
2. Intake air or exhaust leaks. 2. Refer to Excessive Exhaust Smoke
(Refer to 9 - ENGINE - DIAGNOSIS AND
TESTING).
9 - 284 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

EXCESSIVE WHITE SMOKE
POSSIBLE CAUSE CORRECTION
Fuel injector protrusion not correct. Check washer (shim) at bottom of fuel injector for
correct thickness. (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/FUEL INJECTOR - INSTALLATION)
Fuel injection pump malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Fuel supply side restriction to transfer pump. Refer to Powertrain Diagnostic Manual for fuel system
testing.
Fuel transfer (lift) pump malfunctioning. A DTC may have been set. Refer to Powertrain
Diagnostic Procedures Information.
Intake/Exhaust valve adjustments not correct (too tight). (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/
EXHAUST VALVES & SEATS - STANDARD
PROCEDURE).
Intake manifold air temperature sensor malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Intake manifold heater circuit not functioning correctly in
cold weather.A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information. Also check heater
elements for correct operation.
Intake manifold heater elements not functioning
correctly in cold weather.A DTC should have been set if heater elements are
malfunctioning. Refer to Powertrain Diagnostic
Procedures Information.
Internal engine damage (scuffed cylinder). Analyze engine oil and inspect oil filter to locate area of
probable damage.
Restriction in fuel supply side of fuel system. Refer to Powertrain Diagnostic Manual for fuel system
testing.
EXCESSIVE BLUE SMOKE
POSSIBLE CAUSE CORRECTION
Dirty air cleaner or restricted turbocharger intake duct. Check Filter MinderTat air filter housing. (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
ELEMENT - REMOVAL).
Air leak in boost system between turbocharger
compressor outlet and intake manifold.Service air charge system..
Obstruction in exhaust manifold. Remove exhaust manifold and inspect for blockage
(Refer to 9 - ENGINE/MANIFOLDS/EXHAUST
MANIFOLD - REMOVAL).
Restricted turbocharger drain tube. Remove turbocharger drain tube and remove
obstruction.
Crankcase ventilation system plugged. Inspect crankcase ventilation system for function
Valve seals are worn, brittle, or improperly installed. Replace valve stem oil seals (Refer to 9 - ENGINE/
CYLINDER HEAD/INTAKE/EXHAUST VALVES &
SEATS - REMOVAL).
Valve stems and/or guides are worn. Remove valves and inspect valves and guides. (Refer
to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
Broken or Improperly installed piston rings. Tear down engine and inspect piston rings.
DRENGINE 5.9L DIESEL 9 - 287
ENGINE 5.9L DIESEL (Continued)