3.9l v6 Engine [vin X] Dodge Ram II

** PLEASE READ THIS FIRST **

Note. For repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in GENERAL INFORMATION.

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

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 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.

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.

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. Using Fuel Pressure Gauge Set (5069), remove gauge from hose assembly. Place gauge end of hose into an approved gasoline container.
2. Remove fuel rail test port protective cap and place a shop towel under test port. To release fuel pressure, screw other end of hose assembly onto test port. Once all fuel pressure is released, install protective cap on test port.

Removal (Ram Van/Wagon)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x__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, fuel lines, coolant hoses and vacuum hoses. Remove air cleaner, throttle body, drive belts, alternator, fan and fan pulley. Remove lower fan shroud. CAUTION: When removing engine, DO NOT lift engine by intake manifold.
5. Remove intake manifold. See «INTAKE MANIFOLD»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) . 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 . On A/T models, ensure reference marks on torque converter and flexplate are aligned. Evacuate and charge A/C system.

Removal (All Others)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x__fuel-pressure-release). Disconnect and remove battery. On all except Pickup, 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. 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 and fuel lines. Remove throttle body and linkage. Remove intake manifold. Remove starter, alternator, charcoal canister and horns. Disconnect power steering hoses (if equipped). Raise and support vehicle. Drain oil. Disconnect exhaust pipe at exhaust manifold. CAUTION: When removing engine, DO NOT lift engine by intake 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. NOTE: It may be necessary to remove manual transmission if transmission cannot be supported using floor jack.
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. On Dakota 4WD models, go to step 7).
6. On Ram Pickup, remove front engine mount bolts. Remove engine from vehicle. On Dakota 2WD models, remove front engine mount through-bolts. (Scheme 1) Remove engine from vehicle. NOTE: On Dakota 4WD models, the engine, transmission and front axle are connected and supported with insulators and brackets.
7. On left side of Dakota 4WD models, 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.
8. On right side of Dakota 4WD models, 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.

Installation (All Others)

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

Scheme 1

Removal

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x__fuel-pressure-release) . Disconnect negative battery cable. Drain cooling system. Disconnect accelerator, cruise control, and transmission kickdown cables. Disconnect fuel lines at throttle body.
2. Remove engine cover (Ram Van/Wagon), air cleaner, and alternator. 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 2

Installation

1. Install plenum pan and install all bolts finger tight. Tighten bolts to specification, in steps, and in sequence. (Scheme 2) See «TORQUE SPECIFICATIONS»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x).
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 3) See «TORQUE SPECIFICATIONS»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x). To install remaining components, reverse removal procedure.

Scheme 3

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. Repair or replace exhaust manifold if warpage exceeds .004" (.10 mm) overall.

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

1. On Ram Van/Wagon, remove engine cover and heat shields. On all models, disconnect battery and drain coolant. Remove alternator bracket support rod and alternator. Remove intake and exhaust manifold. See «INTAKE MANIFOLD»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) and EXHAUST MANIFOLD.
2. Remove rocker arms and push rods. See «ROCKER ARMS»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x__rocker-arms) . 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 4) See TORQUE SPECIFICATIONS.

Scheme 4

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/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x__water-pump) .
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/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) . Tighten front cover, oil pan and then vibration damper bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) . To complete installation, reverse removal procedure.

1. Remove front cover. See «FRONT COVER»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) . 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. NOTE: When applying torque to camshaft sprocket bolt, DO NOT allow crankshaft to move. It may be necessary to hold crankshaft.
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 5) Remove camshaft sprocket bolt, camshaft sprocket, timing chain and crankshaft sprocket.

1. Install timing chain and sprockets. Ensure timing marks are aligned. (Scheme 5) Install camshaft sprocket bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x).
2. Ensure camshaft end play is within specification. See «CAMSHAFT»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) 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 5

ROCKER ARMS

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 push rod location and remove (if necessary).

1. Locate "V6" mark stamped on vibration damper (147° ATDC). Rotate engine, by hand, until "V6" mark lines up with TDC mark on timing chain cover.
2. On all engines, 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).

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.

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

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/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) .

1. Remove engine. See «ENGINE»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x). Remove front cover and timing chain. See «FRONT COVER»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) and TIMING CHAIN.
2. Remove valve lifters. See «VALVE LIFTERS»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x). Remove distributor and distributor drive shaft. Remove camshaft thrust plate, noting location of oil tab for installation reference. (Scheme 6) Remove camshaft.

Scheme 6

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 7) 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/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x). Top edge of oil tab should be flat against camshaft thrust plate for timing chain lubrication. (Scheme 6)
4. To install remaining components, reverse removal procedure. Check camshaft end play. If end play exceeds specification, replace thrust plate. See «CAMSHAFT»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) table under ENGINE SPECIFICATIONS. Ensure components are installed in original location.

Scheme 7

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/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) 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 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. CAUTION: DO NOT ream distributor drive shaft bushing.
3. Ensure cylinder No. 1 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 cylinder No. 1 in distributor cap.

Removal & Installation (Crankshaft Installed)

1. Remove oil pan. See «OIL PAN»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x). 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 8) Install main bearing cap, and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x). 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 8)

Scheme 8

Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse.

Scheme 9

If thermostat is being replaced, be sure that replacement is specified thermostat for vehicle model and engine type.

Factory installed thermostat housing on 3.9/5.2L engines are installed on a gasket with an anti-stick coating. This will aid in gasket removal and clean-up.

Scheme 10

Scheme 11

1. Disconnect negative battery cable at battery.
2. Drain cooling system until coolant level is below thermostat.
3. Air Conditioned vehicles: Remove support bracket (generator mounting bracket-to-intake manifold) located near rear of generator (Scheme 10)
4. On air conditioning equipped vehicles, the generator must be partially removed. Remove generator drive belt as follows: Drive belts on both 3.9L and 5.2L engines are equipped with a spring loaded automatic belt tensioner (Scheme 11) Attach a socket/wrench to pulley mounting bolt of automatic tensioner (Scheme 11) Rotate tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. Remove belt from vehicle. Remove two generator mounting bolts. Do not remove any wiring at generator. If equipped with 4WD, unplug 4WD indicator lamp wiring harness (located near rear of generator). Remove generator. Position generator to gain access for thermostat gasket removal.
5. Remove upper radiator hose clamp and upper radiator hose at thermostat housing.
6. Position wiring harness (behind thermostat housing) to gain access to thermostat housing.
7. Remove thermostat housing mounting bolts, thermostat housing, gasket and thermostat (Scheme 14) Discard old gasket.

Scheme 12

1. Clean mating areas of intake manifold and thermostat housing.
2. Install thermostat (spring side down) into recessed machined groove on intake manifold (Scheme 14)
3. Install gasket on intake manifold and over thermostat (Scheme 14)
4. Position thermostat housing to intake manifold. Note the word FRONT stamped on housing (Scheme 15) For adequate clearance, this must be placed towards front of vehicle. The housing is slightly angled forward after installation to intake manifold.
5. Install two housing-to-intake manifold bolts. Tighten bolts to 23 N.m (200 in. lbs.) torque.
6. Install upper radiator hose to thermostat housing.
7. Air Conditioned vehicles: CAUTION: When installing the serpentine accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to (Scheme 9) for correct 3.9/5.2L engine belt routing. The correct belt with correct length must be used. Install generator. Tighten bolts to 41 N.m (30 ft. lbs.). Install support bracket (generator mounting bracket-to-intake manifold) (Scheme 10) Tighten bolts to 54 N.m (10 ft. lbs.) torque. Position drive belt over all pulleys except idler pulley (located between generator and A/C compressor). Attach a socket/wrench to pulley mounting bolt of automatic tensioner (Scheme 11) Rotate socket/wrench clockwise. Place belt over idler pulley. Let tensioner rotate back into place. Remove wrench. Be sure belt is properly seated on all pulleys.
8. Fill cooling system.
9. Connect negative battery cable to battery.
10. Start and warm the engine. Check for leaks.

WATER PUMP

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. Fill system with coolant. Ensure accessory drive belt is installed in original direction to ensure proper rotation of water pump. (Scheme 16)

Scheme 13

Removal (Dakota 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)

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 17) Tighten bolts to specification. See TORQUE SPECIFICATIONS. To install remaining components, reverse removal procedure.

Scheme 14

Removal (Dakota 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. CAUTION: DO NOT pull on rubber boot during axle shaft removal. Pull on outer CV joint only.
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)

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 17)
2. 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/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x). Ensure reference marks on transfer case yoke and front drive shaft are aligned.

Removal (Ram Pickup & Ram Van/Wagon)

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)

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 17) Tighten bolts to specification. See TORQUE SPECIFICATIONS. To install remaining components, reverse removal procedure.

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 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/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) 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

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.

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.

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

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.

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

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/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) table under ENGINE SPECIFICATIONS.

Note. Piston diameter and cylinder bore should be measured at room temperature of 70°F (21°C).

Piston Rings

1. Ensure ring end gap and side clearances are within specification. See «PISTONS, PINS & RINGS»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) table under ENGINE SPECIFICATIONS.
2. Position piston ring gaps in proper location. (Scheme 18) 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 15

Rod Bearings

1. Crankshaft is marked to indicate undersize rod bearings. See «SPECIAL ENGINE MARKS»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x__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. Ensure oil clearance and side play are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) table under ENGINE SPECIFICATIONS.

Crankshaft & Main Bearings

1. Crankshaft is marked to indicate undersize main bearings. See «SPECIAL ENGINE MARKS»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x__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/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) 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/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) table. Ensure oil clearance and end play are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) table.

Thrust Bearing

Thrust bearing is located on No. 2 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/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) table under ENGINE SPECIFICATIONS. NOTE: Cylinder bore should be measured at room temperature of 70°F (21°C).
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 table under ENGINE SPECIFICATIONS.

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

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. see scheme 19

Crankcase Capacity

Oil capacity with oil filter is 4.0 qts. (3.8L).

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 16

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. see scheme 20 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" (54.0-57.7 mm) from bottom of block.

Scheme 17

Removal & Disassembly

1. Remove oil pan. See «OIL PAN»(/dodge/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) 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-faced 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. see scheme 21

Scheme 18

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/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) 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/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) 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/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) 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 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/ram/ii-1994-2001/remont/mechanical/#39l-v6-engine-vin-x) 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.

DAKOTA 2WD

TORQUE SPECIFICATIONS (DAKOTA 2WD)

DAKOTA 4WD

TORQUE SPECIFICATIONS (DAKOTA 4WD)

RAM PICKUP

TORQUE SPECIFICATIONS (RAM PICKUP)

RAM VAN/RAM WAGON

TORQUE SPECIFICATIONS (RAM VAN/RAM WAGON)

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

PISTONS, PINS & RINGS

PISTONS, PINS & RINGS

CYLINDER BLOCK

VALVES & VALVE SPRINGS

VALVES & VALVE SPRINGS

CYLINDER HEAD

CAMSHAFT ( 1 )

CAMSHAFT (1)

VALVE LIFTERS

See also:
• ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION
• FUEL PRESSURE RELEASE
• INTAKE MANIFOLD
• ROCKER ARMS
• WATER PUMP
• SPECIAL ENGINE MARKS