3.9l v6 Engine, 5.2l v8 Engine & 5.9l v8 Engine Dodge Pickup R3500

ENGINE IDENTIFICATION

Engine may be identified by eighth character of Vehicle Identification Number (VIN) stamped on metal tab located near lower left corner of windshield. See ENGINE IDENTIFICATION CODES table.

Engine serial number may be required when ordering replacement parts. Engine serial number is located on left front corner of cylinder block just below cylinder head.

ENGINE IDENTIFICATION CODES

SPECIAL ENGINE MARKS

Information identifying undersize and oversize components is found at various engine locations and is decoded as follows

Crankshaft & Rod Journals

1. The letter "M" (main) or "R" (rod) followed by number indicates which main or rod bearing journal is .001" (.02 mm) undersize. The mark is stamped on No. 6 crankshaft counterweight on 3.9L, No. 8 crankshaft counterweight on 5.2L and No. 3 crankshaft counterweight on 5.9L engines.

Cylinder Block

1. Letter "A" following engine serial number indicates .020" (.51 mm) oversize cylinder bores.
2. A diamond-shaped stamp, located on top pad at front of engine and stamped on flat area of each oversize lifter bore, indicates .008" (.20 mm) oversize lifters.
3. A stamp "X" indicates .005" (.13 mm) oversize valve stems. The stamp is found on machined pad, near two 3/8" tapped holes on each end of cylinder head.

VALVE CLEARANCE ADJUSTMENT

Hydraulic valve lifters are used. No valve adjustment is required.

TROUBLE SHOOTING

Note. To trouble shoot mechanical engine components, see appropriate table in TROUBLE SHOOTING article in GENERAL INFORMATION.

REMOVAL & INSTALLATION

Note. For installation reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

FUEL PRESSURE RELEASE

Gasoline

1. Disconnect negative battery cable. Loosen fuel tank cap to release tank pressure. Press on filler tube flap to relieve any additional tank pressure. NOTE: Fuel filler tube has spring-loaded flap located below fuel fill cap to serve as secondary seal if fuel fill cap is not tightened. It is part of EVAP monitor system when vehicle is equipped with leak detection pump (LDP). Vehicle may be equipped with flap installed into fuel filler tube even if vehicle is NOT equipped with LDP and EVAP monitor system.
2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. Start and run engine until it stalls. Attempt restarting engine until it will no longer run.
3. Unplug connector from an injector. Attach one end of a jumper wire (18 gauge or smaller) with alligator clips to either injector terminal. Connect other end of jumper wire to positive side of battery. Connect one end of a second jumper wire to remaining injector terminal. WARNING: Powering an injector for more than a few seconds will permanently damage injector.
4. Touch other end of second jumper wire to negative terminal of battery for no more than a few seconds. Place a rag below fuel line. Disconnect quick-connect fitting at fuel rail. See «FUEL LINE DISCONNECT FITTINGS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) . Return fuel pump relay to PDC.

Compressed Natural Gas Fuel Tube Purging (5.2L)

1. Close control valve (clockwise) on all fuel cylinders. Open manual shutoff valve (open when handle is parallel to fuel tubes).
2. Start and operate engine until it runs out of fuel. Attempt 3 more engine starts. If check valve or fuel fill receptacle is to be serviced, slowly loosen inlet side of fuel fill tube fitting at check valve. It is normal for approximately 25 psi of residual natural gas pressure to flow from loosened fitting. At this point, all fuel tubes are purged of natural gas between fuel cylinders and engine. It is now okay to open fuel system. WARNING: Fuel cylinders still contain high-pressure fuel.

Compressed Natural Gas Fuel Cylinder Purging (5.2L)

1. Open manual shutoff valve. Open only fuel control valve(s) (counterclockwise) on fuel cylinder(s) to be serviced. Close all other control valve(s) (clockwise) on fuel cylinder(s) not being serviced.
2. Start and operate engine until it runs out of fuel. Attempt 3 more engine starts. At this point, all fuel tubes and opened cylinders are purged of natural gas between fuel cylinders and engine. It is now okay to open fuel system. WARNING: Fuel cylinders not being serviced still contain high-pressure fuel.

Removal & Installation (Tab Type Fitting)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine). Disconnect negative battery cable. Ensure area around fuel line and disconnect fitting is clean. Place shop towel around fuel line.
2. On 2-tab connectors, squeeze retainer tabs together and pull fuel tube/quick-connect fitting assembly off of fuel tube nipple. On single-tab connectors, use screwdriver to pry up pull tab. (Scheme 55) Raise pull tab until it separates from quick-connect fitting. Discard old pull tab. Disconnect quick-connect fitting from fuel line.
3. To install, coat fuel tube nipple with clean 30W engine oil. Insert quick-connect fitting into fuel tube until stop on fuel tube rests against back of quick-connect fitting.
4. On single-tab connectors, obtain NEW pull tab. Push tab down until it locks into quick-connect fitting. On 2-tab connectors, firmly pull on fuel tube and fitting to ensure retainer and quick-connect fitting are locked.

Removal & Installation (Retainer Type Fitting)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine). Disconnect negative battery cable. Ensure area around fuel line and disconnect fitting is clean. Place shop towel around fuel line.
2. Pull backward on disconnect fitting while depressing plastic ring into disconnect fitting. (Scheme 56) Separate fuel line from disconnect fitting. NOTE: Plastic retainer ring must be pressed squarely into fitting body. If retainer is cocked during removal, it may be difficult to disconnect fitting. Use open-end wrench on shoulder of plastic retainer to ease disconnection.
3. To install, ensure plastic ring is in outward position (away from disconnect fitting). If plastic ring is in inward position (toward disconnect fitting), disconnect fitting must be replaced.
4. Lubricate end of fuel line with 30W engine oil. Insert fuel line into disconnect fitting until shoulder on fuel line locks in place.
5. Pull on fuel line and disconnect fitting to ensure fuel line is locked in place. If fuel line is not locked in place, ensure plastic ring is not causing locking retainer to remain in released position. Reconnect negative battery cable. Start engine and check for leaks.

Scheme 55

Scheme 56

Removal (Ram Van/Wagon)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine__fuel-pressure-release) . Disconnect negative battery cable. Drain cooling system and engine oil. Remove and discard oil filter.
2. Remove engine cover, air cleaner and oil dipstick. Discharge A/C system (if equipped) using approved refrigerant recovery/recycling equipment. Disconnect A/C lines at condenser, and plug openings. Remove A/C compressor. Disconnect fan shroud.
3. Remove front bumper, grille and support brace. Disconnect coolant hoses. Remove radiator, condenser and support as an assembly.
4. Remove upper fan shroud. Remove power steering pump with hoses attached, and set aside. Remove air pump, spark plug wires and distributor cap. Disconnect necessary electrical wiring, coolant hoses and vacuum hoses. Disconnect fuel lines. See «FUEL LINE DISCONNECT FITTINGS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) . Remove air cleaner, throttle body, drive belts, generator, fan and fan pulley. Remove lower fan shroud.
5. Remove intake manifold. See «INTAKE MANIFOLD»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) . Raise and support vehicle. Remove starter. Remove exhaust pipe and heat shields. Disconnect transmission shift linkage. Remove crank sensor.
6. On A/T models, remove transmission inspection cover. Mark torque converter-to-flexplate position for installation reference. Remove torque converter-to-flexplate bolts. On M/T models, disconnect clutch release mechanism at clutch housing.
7. Attach engine hoist to cylinder heads (at intake manifold flanges). On all models, support transmission using a floor jack. Remove transmission or clutch housing-to-cylinder block bolts. Remove engine mount bolts. Remove engine out front of vehicle.

Installation (Ram Van/Wagon)

To install, reverse removal procedure. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS table. On A/T models, ensure reference marks on torque converter and flexplate are aligned. Evacuate and charge A/C system.

Removal (Dakota 2WD, Durango 2WD, Grand Cherokee & Ram Pickup)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine__fuel-pressure-release). Disconnect and remove battery. On all except Pickup, scribe hood hinges for installation reference and remove hood.
2. On all models, drain cooling system. Disconnect coolant hoses. Remove radiator, fan and shroud. Discharge A/C system (if equipped) using approved refrigerant recovery/recycling equipment. Disconnect A/C lines, and plug openings. On Pickup, remove upper core support, transmission cooler and A/C condenser. On all models, remove belt, air cleaner, vacuum lines, distributor cap and wiring.
3. Disconnect necessary electrical wiring. Disconnect fuel lines. See «FUEL LINE DISCONNECT FITTINGS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine). Remove throttle body and linkage. Remove intake manifold. Remove starter, generator, charcoal canister and horns. Disconnect power steering hoses (if equipped). Raise and support vehicle. Drain oil. Disconnect exhaust pipe at exhaust manifold.
4. On A/T models, remove transmission housing inspection plate. Mark torque converter-to-flexplate position for installation reference. Remove torque converter-to-flexplate bolts. Remove bracket for transmission cooler lines.
5. On M/T models, disconnect clutch release mechanism at clutch housing. On all models, support transmission using a floor jack. Remove transmission or clutch housing-to-cylinder block bolts. Install engine lifting fixture, and attach chain.
6. On Ram Pickup and Grand Cherokee, remove front engine mount bolts. Remove engine from vehicle. On Dakota 2WD and Durango 2WD models, remove front engine mount through-bolts. (Scheme 57) Remove engine from vehicle.

Installation (Dakota 2WD, Durango 2WD, Grand Cherokee & Ram Pickup)

To install, reverse removal procedure. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS table. On A/T models, ensure reference marks on torque converter and flexplate are aligned. Evacuate and charge A/C system.

Removal (Durango 4WD & Dakota 4WD)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine__fuel-pressure-release). Disconnect and remove battery. Scribe hood hinges for installation reference and remove hood.
2. Drain cooling system. Disconnect coolant hoses. Remove radiator, fan and shroud. Discharge A/C system (if equipped) using approved refrigerant recovery/recycling equipment. Disconnect A/C lines, and plug openings. Remove air cleaner, vacuum lines, distributor cap and wiring.
3. Disconnect necessary electrical wiring. Disconnect fuel lines. See «FUEL LINE DISCONNECT FITTINGS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine). Disconnect accelerator linkage. Remove throttle body. Remove starter and generator. Disconnect power steering hoses. Raise and support vehicle. Drain oil. Disconnect exhaust pipe at exhaust manifold. NOTE: Engine, transmission and front axle are connected and supported with insulators and brackets. (Scheme 57)
4. On left side, remove 2 bolts attaching differential pinion nose bracket-to-bellhousing bolts. Remove pinion nose bracket-to-adapter bolts (located on top of differential, near pinion). Separate engine from engine mount by removing engine mount through-bolt and nut located on top of engine mount.
5. On right side, remove 2 axle-to-bracket bolts and bracket-to-bellhousing bolt. Separate engine from engine mount by removing engine mount through-bolt and nut located on top of engine mount. Remove engine from vehicle.

Scheme 57

Installation (Durango 4WD & Dakota 4WD)

To install, reverse removal procedure. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS table. On A/T models, ensure reference marks on torque converter and flexplate are aligned. Evacuate and charge A/C system.

Removal

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine__fuel-pressure-release) . Disconnect negative battery cable. Drain cooling system. Disconnect accelerator, cruise control, and transmission kickdown cables. Disconnect fuel lines at throttle body. See «FUEL LINE DISCONNECT FITTINGS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) .
2. Remove engine cover (Ram Van/Wagon), air cleaner and generator. Disconnect necessary electrical wiring, coolant hoses and vacuum hoses. Remove distributor cap and spark plug wires. Remove valve covers (if necessary).
3. Remove bolts, intake manifold and gaskets. Separate throttle body from intake manifold (if necessary). Turn intake manifold upside-down and remove plenum pan (if necessary).

Scheme 58

Installation

1. Install plenum pan and install all bolts finger tight. Tighten bolts to specification, in steps, and in sequence. (Scheme 58) See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table.
2. Install manifold flange gaskets on cylinder head with MANIFOLD SIDE words visible. Place a 13/64" (5 mm) bead of silicone rubber adhesive sealant at 4 corner joints. Install front and rear gaskets. Ensure holes in front and rear gaskets engage with dowels in cylinder block.
3. Install intake manifold and install all bolts finger tight. Tighten bolts to specification, in steps, and in sequence. (Scheme 59)and (Scheme 60). See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table. To install remaining components, reverse removal procedure.

Scheme 59

Scheme 60

Disconnect negative battery cable. Raise and support vehicle. Disconnect exhaust pipe from exhaust manifold. Lower vehicle. Remove exhaust heat shields (if equipped). Remove bolts, nuts, washers and exhaust manifold. Note location of conical washer on bolts/studs. Remove manifold.

Inspection

Check exhaust manifold mating surface warpage. On 3.9L or 5.2L, repair or replace exhaust manifold if warpage exceeds .004" (.10 mm) overall. On 5.9L applications, repair or replace exhaust manifold if warpage exceeds .008" (.20 mm) per 12" (305 mm).

To install, reverse removal procedure. Ensure conical washers are installed in original locations. Tighten bolts/nuts to specification, starting at center and working outward. See TORQUE SPECIFICATIONS table.

1. On Ram Van/Wagon, remove engine cover and heat shields. On all models, disconnect battery, and drain coolant. Remove generator bracket support rod and generator. Remove intake and exhaust manifold. See «INTAKE MANIFOLD»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) and «EXHAUST MANIFOLD»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) .
2. Remove rocker arms and push rods. See «ROCKER ARMS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) . Remove cylinder head bolts, cylinder head and gasket.

Check cylinder head warpage. Repair or replace cylinder head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.

To install, reverse removal procedure. Tighten cylinder head bolts, to specification and in sequence, using 3 steps. (Scheme 61) See TORQUE SPECIFICATIONS table.

Scheme 61

Disconnect negative battery cable. Remove drive belts from crankshaft pulley. Remove fan and shroud. Remove crankshaft pulley and vibration damper. Pry oil seal from front cover.

1. Use Seal Installer (6635) for seal installation. Installer should fit with minimum interference. If installer does not fit, front cover must be removed and installed properly.
2. Position small diameter of oil seal over seal installer. Using vibration damper bolt, tighten seal installer to draw seal into position. Remove vibration damper bolt and seal installer. To complete installation, reverse removal procedure.

1. Disconnect battery. Drain coolant. Remove power steering pump (if equipped). Remove water pump. See «WATER PUMP»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) .
2. Remove crankshaft pulley and vibration damper. Loosen oil pan bolts. Remove oil pan-to-front cover bolts on each side of oil pan. Remove bolts, front cover and gasket. DO not damage oil pan gasket.

1. Ensure sealing surfaces are clean. Apply a 1/8" (3.17 mm) bead of RTV sealant to oil pan gasket. Install gasket, front cover and bolts. DO NOT tighten bolts at this time.
2. Install front cover oil seal. See «FRONT COVER OIL SEAL»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) . Tighten front cover, oil pan and then vibration damper bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table. To complete installation, reverse removal procedure.

1. Remove front cover. See «FRONT COVER»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) . Position ruler at camshaft sprocket, near timing chain link, to check timing chain stretch.
2. Place torque wrench on camshaft sprocket bolt. Apply 30 ft. lbs. (41 N.m) torque with cylinder heads installed, or 15 ft. lbs. (20 N.m) with cylinder heads removed, on camshaft sprocket bolt in direction of engine rotation. Note reading on ruler.
3. Apply same amount of torque in opposite direction and note amount of timing chain movement on ruler. If movement exceeds 1/8" (3.17 mm), replace timing chain.

Rotate crankshaft so timing marks are aligned. (Scheme 62) Remove camshaft sprocket bolt, camshaft sprocket, timing chain and crankshaft sprocket.

1. Install timing chain and sprockets. Ensure timing marks are aligned. (Scheme 62) Install camshaft sprocket bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table.
2. Ensure camshaft end play is within specification. See «CAMSHAFT»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table under ENGINE SPECIFICATIONS. If end play is not within specification, replace thrust plate located between camshaft sprocket and camshaft. To install remaining components, reverse removal procedure.

Scheme 62

Disconnect spark plug wires, PCV and fuel evaporation hoses. Remove valve covers. Remove bolts, pivots, and rocker arms. Wire components together for installation reference. Mark each push rod for location, and remove (if necessary).

1. On 3.9L engine, locate "V6" mark stamped on vibration damper (147 degrees ATDC). Rotate engine by hand until "V6" mark lines up with TDC mark on timing chain cover.
2. On 5.2L and 5.9L engines, locate "V8" mark stamped on vibration damper (147 degrees ATDC). Rotate engine by hand until "V8" mark lines up with TDC mark on timing chain cover.
3. Install rocker arm and pivot assemblies and tighten bolt to 21 ft. lbs. (28 N.m). Wait 5 minutes before starting engine to allow valve lifters to bleed down after rocker arm installation. To install remaining components, reverse removal procedure. Tighten valve cover bolts to 95 INCH lbs. (11 N.m).

Remove air cleaner. Remove rocker arms. See ROCKER ARMS . Remove intake manifold. See INTAKE MANIFOLD . Remove yoke retainer and aligning yoke. Use Valve Lifter Remover/Installer (C-4129-A) to remove valve lifter(s).

Note. Cylinder block must be marked to indicate oversize valve lifters. See SPECIAL ENGINE MARKS under ENGINE IDENTIFICATION.

Inspect components for damage. Measure lifter O.D. and bore diameter in cylinder block. Determine oil clearance. Clearance must be within specification. See VALVE LIFTERS table under ENGINE SPECIFICATIONS. Cylinder block can be bored for oversize lifters.

1. Lubricate valve lifters and push rods before installing in original locations. Ensure valve lifter is installed so oil feed hole in side of valve lifter is facing upward, away from crankshaft.
2. Align yokes with arrow pointing toward camshaft. Install yoke retainer, and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table.

1. Remove engine. See «ENGINE»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine). Remove front cover and timing chain. See «FRONT COVER»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) and «TIMING CHAIN»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine).
2. Remove valve lifters. See «VALVE LIFTERS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine__valve-lifters). Remove distributor and distributor drive shaft. Remove camshaft thrust plate, noting location of oil tab for installation reference. (Scheme 63) Remove camshaft.

Scheme 63

Inspect camshaft and camshaft bearings for wear. Measure camshaft journal diameter and camshaft bearing I.D. Replace camshaft or camshaft bearings if not within specification. See CAMSHAFT table under ENGINE SPECIFICATIONS.

1. Ensure cup plugs are installed in oil passages behind thrust plate. Lubricate camshaft and bearings, and install within 2" (50.8 mm) of final installation location.
2. Install Camshaft Installer (C-3509), with long area behind distributor drive gear. (Scheme 64) This prevents camshaft from contacting plug located in rear of cylinder block. Install distributor lock bolt to retain camshaft installer.
3. Install camshaft thrust plate and oil tab. Ensure tang engages with lower right hole of camshaft thrust plate. Tighten camshaft thrust plate bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table. Top edge of oil tab should be flat against camshaft thrust plate for timing chain lubrication. (Scheme 63)
4. To install remaining components, reverse removal procedure. Check camshaft end play. If end play exceeds specification, replace thrust plate. See «CAMSHAFT»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table under ENGINE SPECIFICATIONS. Ensure components are installed in original location.

Scheme 64

1. Use Camshaft Bearing Remover/Installer (C-3132-A) for camshaft bearing replacement. Replace camshaft bearing if damaged or if I.D. is not within specification. See «CAMSHAFT»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table under ENGINE SPECIFICATIONS.
2. Ensure oil holes are aligned. Ensure oil hole in No. 2 bearing aligns with oil hole to left cylinder head, and oil hole in No. 3 bearing (3.9L) or No. 4 bearing (5.2L and 5.9L) aligns with oil hole to right cylinder head. Install NEW camshaft plug at rear of cylinder block.

1. Rotate crankshaft so No. 1 cylinder is at TDC on compression stroke. Remove distributor and distributor drive shaft. Insert Bushing Puller (C-3052) into bushing, and thread down until tight.
2. Hold bushing puller bolt, and rotate bushing puller nut until distributor drive shaft bushing is removed.

1. Install NEW distributor drive shaft bushing over burnishing end of Bushing Installer (C-3053). Insert bushing installer and distributor drive shaft bushing into cylinder block.
2. Using hammer, drive bushing installer and distributor drive shaft bushing into cylinder block. Tighten nut to pull bushing installer through distributor drive shaft bushing. Tightening nut expands bushing tight in cylinder block and burnishes it to correct size.
3. Ensure No. 1 cylinder is at TDC on compression stroke. Install distributor drive shaft so slot is aligned toward left front intake manifold bolt as viewed from rear of engine. Install distributor with rotor positioned to No. 1 cylinder in distributor cap.

Removal & Installation (Crankshaft Installed)

1. Remove oil pan. See «OIL PAN»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine). Remove oil pump. Remove rear main bearing cap and discard lower rear crankshaft oil seal. Carefully remove upper rear crankshaft oil seal and discard seal.
2. Lubricate new oil seal. Rotate upper rear crankshaft oil seal in cylinder block with Yellow paint toward rear of engine. Install lower rear crankshaft oil seal in main bearing cap with Yellow paint toward rear of engine.
3. To prevent oil leakage, apply one drop of Loctite 515 sealant next to oil seal on main bearing cap surface before installing. Apply silicone adhesive sealant at bearing cap-to-cylinder block joint. (Scheme 65) Install main bearing cap, and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table. To install remaining components, reverse removal procedure.

Removal & Installation (Crankshaft Removed)

1. Remove rear crankshaft oil seals from cylinder block and main bearing cap. Lubricate oil seal. Install rear crankshaft oil seals with Yellow paint toward rear of engine.
2. To prevent oil leakage, apply one drop of Loctite 515 sealant next to oil seal on main bearing cap surface before installing. Apply silicone adhesive sealant at bearing cap-to-cylinder block joint. (Scheme 65)

Scheme 65

1. Disconnect negative battery cable. Drain cooling system. Remove throttle cable at top of fan shroud. Unsnap coolant overflow tank from fan shroud and lay aside. DO NOT disconnect coolant hose.
2. Remove upper radiator hose. Using Fan Wrench (SP346) from Set (2017DSP), remove fan clutch assembly from water pump by turning nut counterclockwise as viewed from front. DO NOT remove fan clutch assembly at this time.
3. Remove fan shroud bolts and clips. Remove fan shroud and fan clutch assembly as a unit. Locate accessory drive belt tensioner, and rotate tensioner clockwise (counterclockwise on heavy-duty cycle engines) to release tension on accessory drive belt.
4. Note drive belt routing for installation reference. Belt must be correctly routed during installation, or engine will overheat due to water pump rotating in wrong direction.
5. Remove bolts and water pump pulley. Disconnect lower radiator hose and heater hoses. Remove coolant return tube from water pump. Remove bolts, water pump and gasket.

To install, reverse removal procedure using NEW gasket. Tighten bolts to specification. See TORQUE SPECIFICATIONS table. Fill system with coolant. Ensure accessory drive belt is installed in original direction to ensure proper rotation of water pump. (Scheme 66)

Scheme 66

Scheme 67

Removal (Dakota 2WD & Durango 2WD)

1. Disconnect negative battery cable. Remove oil dipstick and distributor cap. Raise and support vehicle. Drain engine oil.
2. Remove exhaust pipe. Remove side engine mount bolts. Slightly raise engine. When engine is at adequate height, install bolts in side engine mount-to-frame bracket holes to support engine.
3. Lower engine, and allow it to rest on bolts installed in side engine mounts. Remove oil pan bolts, oil pan and gaskets.

Installation (Dakota 2WD & Durango 2WD)

1. To install, reverse removal procedure. Before installing oil pan, apply RTV sealant where front cover contacts cylinder block, where oil pan side gaskets meet end seals, and where end seals contact cylinder block. (Scheme 72)
2. To facilitate oil pan installation, fabricate 4 alignment dowels from 1 1/2" x 5/16" bolts. (Scheme 68) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table. To install remaining components, reverse removal procedure.

Removal (Dakota 4WD & Durango 4WD)

1. Disconnect negative battery cable. Remove oil dipstick. Drain engine oil. Remove exhaust pipe crossover and lower transmission cover.
2. Remove front drive axle for access to oil pan. For front drive axle removal, loosen wheel lug nuts. Remove cotter pin, lock nut and spring washer. Loosen axle shaft nut with vehicle on floor and brakes applied. Raise and support vehicle.
3. Remove wheels and skid plate. Remove axle shaft nut. Remove axle shaft-to-differential flange bolts at front drive axle. Support axle shaft, and separate axle splines from wheel hub by pulling inward at outer CV joint.
4. Remove remaining axle shaft. Mark front drive shaft and transfer case yoke for installation reference. Remove front drive shaft from transfer case. Disconnect vacuum hoses from shift motor and electrical connections at shift indicator switch.
5. Support front drive axle using a floor jack. Remove front drive axle and shift motor bolts. Lower floor jack, and remove front drive axle with drive shaft. Remove transmission lower cover. Remove bolts, oil pan and gasket.

Installation (Dakota 4WD & Durango 4WD)

1. To install, reverse removal procedure. Before installing oil pan, apply RTV sealant where front cover contacts cylinder block, oil pan side gaskets meet end seals and end seals contact cylinder block. (Scheme 72)
2. To facilitate oil pan installation, fabricate 4 alignment dowels from 1 1/2" x 5/16" bolts. (Scheme 68) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table.
3. To install remaining components, reverse removal procedure. When installing front drive axle, loosely install all bolts before tightening to specification. Tighten axle shaft nut to specification with vehicle on ground. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table. Ensure reference marks on transfer case yoke and front drive shaft are aligned.

Removal (Ram Pickup & Ram Van/Wagon - 3.9L)

1. Disconnect negative battery cable. Remove oil dipstick. On Ram Van/Wagon, remove engine cover. On all models, remove air cleaner and engine controller. Raise and support vehicle. Drain engine oil.
2. Remove left engine-to-transmission strut. Loosen exhaust pipe support bracket. Disconnect exhaust pipe. On Ram Pickup, remove oil pan and gasket.
3. On Ram Van/Wagon, remove starter, transmission dust shield, oxygen sensor and air injection tube. On all models, remove right engine mount nut. Loosen, but DO NOT remove, left engine mount nut.
4. Support right side of engine using jackstand. Remove transmission mount through-bolt, and support transmission using jackstand. Raise engine and transmission enough for oil pan removal. Remove bolts, oil pan and gasket.

Installation (Ram Pickup & Ram Van/Wagon - 3.9L)

1. To install, reverse removal procedure. Before installing oil pan, apply RTV sealant where front cover contacts cylinder block, oil pan side gaskets meet end seals and end seals contact cylinder block. (Scheme 72)
2. To facilitate oil pan installation, fabricate 4 alignment dowels from 1 1/2" x 5/16" bolts. (Scheme 68) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table. To install remaining components, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table. To install remaining components, reverse removal procedure.

Removal (Ram Pickup - 5.2L & 5.9L)

1. Disconnect the negative cable from the battery.
2. Remove engine oil dipstick.
3. Raise vehicle.
4. Drain engine oil.
5. Remove exhaust pipe.
6. Remove left engine-to-transmission strut.
7. Loosen the right side engine support bracket cushion thru-bolt nut and raise the engine slightly. Remove oil pan by sliding backward and out.
8. Remove the one-piece gasket.

Installation (Ram Pickup - 5.2L & 5.9L)

1. Clean block and pan gasket surfaces.
2. Trim or remove excess sealant film in the rear main cap oil pan gasket groove. DO NOT remove the sealant inside the rear main cap slots.
3. If present, trim excess sealant from inside the engine.
4. Fabricate 4 alignment dowels from 5/16 x 1 1/2 inch bolts. Cut the head off the bolts and cut a slot into the top of the dowel. This will allow easier installation and removal with a screwdriver. (Scheme 68)
5. Install the dowels in the cylinder block. (Scheme 68)
6. Apply small amount of Mopar® Silicone Rubber Adhesive Sealant, or equivalent in the corner of the cap and cylinder block.
7. Slide the one-piece gasket over the dowels and onto the gasket.
8. Install the oil pan bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine__torque-specifications).
9. Remove the dowels. Install the remaining oil pan bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine__torque-specifications).
10. Lower the engine into the support cushion brackets and tighten the thru-bolt nut to the proper torque. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine__torque-specifications).
11. Install the drain plug. Tighten the drain plug to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine__torque-specifications).
12. Install the engine-to-transmission strut.
13. Install exhaust pipe.
14. Lower vehicle.
15. Install dipstick.
16. Connect the negative cable to the battery.
17. Fill crankcase with oil to proper level.

Scheme 68

Removal (Ram Van/Wagon - 5.2L & 5.9L)

1. Disconnect battery negative cable.
2. Remove engine oil dipstick
3. Remove air cleaner inlet duct.
4. Unbolt the engine controller from the cowl and secure out of the way. DO NOT disconnect.
5. Remove upper cooling fan shroud fasteners.
6. Remove engine cover. (Scheme 69)
7. Raise vehicle on hoist.
8. Drain engine oil.
9. Remove transmission oil cooler lines from the oil pan mounting clip.
10. Remove engine to transmission support braces.
11. Remove starter motor.
12. Remove transmission inspection cover.
13. Remove left and right engine mount insulator nuts. (Scheme 70)and (Scheme 71).
14. Remove the oil pan fasteners.
15. Remove the oil pan from the vehicle.

Scheme 69

Scheme 70

Scheme 71

Installation (Ram Van/Wagon - 5.2L & 5.9L)

1. Fabricate 4 alignment dowels from 5/16 x 1 1/2 inch bolts. Cut the head off the bolts and cut a slot into the top of the dowel. This will allow easier installation and remove with a screwdriver. (Scheme 68)
2. Install the dowels in the cylinder block. (Scheme 68)
3. Apply a small amount of Mopar® Silicone Rubber Adhesive Sealant, or equivalent in the corner of the cap and cylinder block.
4. Slide the one piece gasket over the dowels and onto the block.
5. Position the oil pan over the dowels and onto the gasket.
6. Install the oil pan bolts. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine__torque-specifications).
7. Remove the dowels. Install the tighten the remaining pan bolts. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine__torque-specifications).
8. Install and tighten the oil pan drain plug to specified torque. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine__torque-specifications).
9. Lower the engine while aligning the engine mount insulators with the brackets.
10. Install the mount insulator nuts and tighten to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine__torque-specifications).
11. Install the transmission inspection cover.
12. Install the starter motor.
13. Install the engine to transmission support brackets.
14. Install the transmission oil cooler lines into the mounting clips.
15. Lower the vehicle.
16. Install the upper cooling
17. Fasten the controller to the cowl.
18. Install the air cleaner inlet duct.
19. Install the engine oil dipstick.
20. Fill the crankcase with engine oil.
21. Connect the battery negative cable.
22. Start engine and check for leaks.

Removal (Grand Cherokee)

Disconnect negative battery cable. Remove oil dipstick. Raise and support vehicle. Drain engine oil. Disconnect O2 sensor. Remove exhaust pipe and starter. Remove left engine-to-transmission strut. Disconnect oil level sensor (if equipped). Remove bolts, oil pan and gasket. DO NOT damage oil level sensor.

Installation (Grand Cherokee)

1. To install, reverse removal procedure. Before installing oil pan, apply RTV sealant where front cover contacts cylinder block, oil pan side gaskets meet end seals and end seals contact cylinder block. (Scheme 72)
2. To facilitate oil pan installation on all models, fabricate 4 alignment dowels from 1 1/2" x 5/16" bolts. (Scheme 68) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table. To install remaining components, reverse removal procedure.

Scheme 72

Cylinder Head

Check cylinder head warpage. Repair or replace cylinder head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.

Valve Springs

1. Check valve spring free length, out-of-square and pressure. Replace valve spring if not within specification. See «VALVES & VALVE SPRINGS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table under ENGINE SPECIFICATIONS.
2. Measure valve spring installed height from bottom of spring seat (cylinder head surface) to bottom of spring retainer. If spacers are installed, measure from top of spacer.
3. If height exceeds 1.687" (42.86 mm), install a .066" (1.58 mm) thick spacer in cylinder head counterbore to obtain correct installed spring height. See «VALVES & VALVE SPRINGS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table.

Valve Stem Oil Seals

Cup-type oil seals are used on all valves. Ensure oversize valve stem oil seals are used when oversize valves are installed. When installing valves, DO NOT overcompress valve springs, or damage to valve stem oil seal may result.

Valve Guides

Note. DO NOT ream valve guides from standard to maximum oversize in one step. Ream valve guides to oversize in gradual steps so guides are reamed true in relation to valve seat. After reaming valve guides, valve seat runout must be checked.

Check valve stem oil clearance. Ensure valve stem diameter is within specification. Valve guide must be reamed for valve with oversize valve stem if oil clearance exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Valves are available with stems of .015" (.38 mm) and .030" (.76 mm) oversize.

Valve Seat

Check valve seat width and runout. Grind valve seat if not within specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.

Valves

Ensure valve margin, head diameter and stem diameter are within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS. Valves are available with stems of .015" (.38 mm) and .030" (.76 mm) oversize.

Valve Seat Correction Angles

Use a 15-degree stone to lower valve seat, and a 60-degree stone to raise valve seat.

Rocker Arms & Pivots

Remove rocker arms and pivots. Inspect for wear. Replace as necessary.

Valve Lifters

Note. Cylinder block must be marked to indicate oversize valve lifters. See SPECIAL ENGINE MARKS .

Measure valve lifter diameter and bore diameter in cylinder block. Determine oil clearance. Clearance must be within specification. See VALVE LIFTERS table under ENGINE SPECIFICATIONS. Cylinder block can be bored for oversize lifters.

Piston & Rod Assembly

Install piston with notch or groove on top of piston toward front of engine (timing chain end) with larger chamfer of connecting rod bore toward crankshaft journal fillet.

Fitting Pistons

1. Measure piston diameter at top of piston skirt at 90-degree angle to piston pin axis. Measure cylinder bore diameter below top surface of cylinder bore, middle of bore and bottom of cylinder bore.
2. Ensure piston diameter and clearance are within specification. See «PISTONS, PINS & RINGS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table under ENGINE SPECIFICATIONS.

Piston Rings

1. Ensure ring end gap and side clearances are within specification. See «PISTONS, PINS & RINGS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table under ENGINE SPECIFICATIONS.
2. Position piston ring gaps in proper location. (Scheme 73) Compression ring gaps must be staggered so they do not align with oil ring rail gap. Ensure identification marks (drill point, letter "O", an oval depression or the word TOP) on compression rings face upward.

Scheme 73

Rod Bearings

1. Crankshaft is marked to indicate undersize rod bearings. See «SPECIAL ENGINE MARKS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine__special-engine-marks) . When replacing connecting rod bearings, ensure connecting rod is installed with larger chamfer of connecting rod bore toward crankshaft journal fillet.
2. Apply light coat of engine oil to connecting rod bolt threads before tightening nut to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table. Ensure oil clearance and side play are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table under ENGINE SPECIFICATIONS.

Crankshaft & Main Bearings

1. Crankshaft is marked to indicate undersize main bearings. See «SPECIAL ENGINE MARKS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine__special-engine-marks) . Main bearing cap location and direction of installation should be marked before removal.
2. Ensure journal diameter, taper and out-of-round are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table under ENGINE SPECIFICATIONS. Upper main bearings contain oil holes, while lower bearings installed in main bearing cap do not.
3. Apply light coat of engine oil to threads before tightening bolt to specification. See «TORQUE SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table. Ensure oil clearance and end play are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table.

Thrust Bearing

Thrust bearing is located on No. 3 main bearing. Replace thrust bearing if crankshaft end play is not within specification. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.

1. Check cylinder bore, out-of-round and taper. Measure cylinder bore diameter below top surface of cylinder bore, middle of bore and bottom of cylinder bore. Bore cylinder block if bore diameter is not within specification. See «CYLINDER BLOCK»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table under ENGINE SPECIFICATIONS.
2. Check valve lifter bore diameter. Check for scoring. If scoring exists or lifter bore diameter is not within specification, ream cylinder block bore for next oversize valve lifter. See «VALVE LIFTERS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table under ENGINE SPECIFICATIONS.

ENGINE LUBRICATION SYSTEM

System has a rotor-type oil pump and full-flow oil filter. Oil is forced by pump through a series of oil passages in engine to provide lubrication to engine components. Oil is supplied to rocker assembly through hollow push rods. Push rods are fed oil from lifters. (Scheme 74)

Crankcase Capacity

On 3.9L, oil capacity with oil filter is 4.0 qts. (3.8L). On 5.2L and 5.9L, oil capacity with oil filter is 5.0 qts. (4.7L).

Oil Pressure

Oil pressure is 6 psi (.4 kg/cm 2 ) at idle and 30-80 psi (2.1-5.6 kg/cm 2 ) at 3000 RPM with engine at normal operating temperature.

Scheme 74

OIL LINE PLUG

1. The oil line plug is located in vertical passage in rear of block between oil-to-filter and oil-from-filter passages. (Scheme 75) Missing or improperly installed plug could cause erratic, low or no oil pressure.
2. To check installation, remove oil sending unit and insert wire down passage. Oil line plug should be 7.50-7.68 in. (190.0-195.2 mm) from machined surface of block. If plug is too high, use suitable dowel to position properly. If plug is too low, remove oil pan, oil pump and rear main bearing cap. Use suitable dowel to position properly.
3. To remove for passage cleaning or plug replacement, drive plug from oil sending unit hole out bottom of block. When installing plug, coat outside diameter with Mopar Stud and Bearing Mount Adhesive or equivalent. Plug should be 2.12-2.31 in. (54.0-57.7 mm) from bottom of block.

Scheme 75

Removal & Disassembly

1. Remove oil pan. See «OIL PAN»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) under REMOVAL & INSTALLATION. Remove bolts and oil pump from rear main bearing cap.
2. Remove cotter pin. Drill a 1/8" (3.17 mm) hole into relief valve retainer cap and insert a self-tapping sheet metal screw into cap. Clamp screw into vise. While supporting pump, remove retainer cap by tapping pump body using soft-face hammer.
3. Discard retainer cap, and remove spring and relief valve. Remove pump cover and discard oil seal ring. Remove inner rotor and shaft and outer rotor. (Scheme 76)

Scheme 76

1. Inspect components for damage. Using feeler gauge and straightedge, check pump cover flatness. Measure thickness of inner and outer rotors. Measure outer rotor outside diameter. Replace rotors if not to specification. See «OIL PUMP SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table.
2. Install outer rotor into pump body. Press outer rotor to one side, and measure clearance between outer rotor and pump body. Replace oil pump assembly if clearance exceeds specification. See «OIL PUMP SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table.
3. With outer rotor installed in pump body, install inner rotor and shaft into pump body. Measure rotor tip clearance between inner and outer rotors. Replace rotors if clearance exceeds specification. See «OIL PUMP SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table.
4. With rotors installed in pump body, place a straightedge (between bolt holes) across face of pump body. Measure rotor end clearance between rotors and straightedge. Replace oil pump assembly if clearance exceeds specification. See «OIL PUMP SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table.
5. Ensure relief valve slides freely in bore. Check free length and tension of relief valve spring. Replace spring if not within specification. See «OIL PUMP SPECIFICATIONS»(/dodge/pickup-r3500/1998-1999/remont/mechanical/#39l-v6-engine-52l-v8-engine-59l-v8-engine) table.

OIL PUMP SPECIFICATIONS

Reassembly & Installation

To reassemble, reverse disassembly procedure. Install NEW relief valve retainer cap and oil seal ring. Tighten pump cover bolts. Fill rotor cavity with engine oil before installing. To install, reverse removal procedure.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL SPECIFICATIONS (3.9L)

GENERAL SPECIFICATIONS (3.9L)

GENERAL SPECIFICATIONS (5.2L)

GENERAL SPECIFICATIONS (5.2L)

GENERAL SPECIFICATIONS (5.9L)

GENERAL SPECIFICATIONS (5.9L)

CRANKSHAFT, MAIN BEARINGS & CONNECTING ROD BEARINGS SPECIFICATIONS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

PISTONS, PISTON PINS & PISTON RINGS SPECIFICATIONS

PISTONS, PINS & RINGS

ENGINE VALVES & VALVE SPRINGS SPECIFICATIONS

VALVES & VALVE SPRINGS

CYLINDER HEAD SPECIFICATIONS

CYLINDER HEAD

CAMSHAFT SPECIFICATIONS

CAMSHAFT (1)

CYLINDER BLOCK SPECIFICATIONS

CYLINDER BLOCK

VALVE LIFTERS SPECIFICATIONS

VALVE LIFTERS

See also:
• ENGINE IDENTIFICATION CODES
• FUEL PRESSURE RELEASE
• SPECIAL ENGINE MARKS
• VALVE LIFTERS
• TORQUE SPECIFICATIONS