2001 Dodge Ram 1500, 2500 & 3500 Service Manual for: 3.9 L 6 cyl. MPI Gasoline (5.9L), 5.2 L 8 cyl. MPI Gasoline (5.2L), 5.2 L 8 cyl. (CNG) (5.2L), 5.9 L 8 cyl. MPI Gasoline, 5.9 L 8 cyl. MPI Gasoline (Heavy Duty) (5.9L), 5.9 L 6 cyl. Turbo Diesel (5.9L), 8.0 L 10 cyl. MPI Gasoline (8.0L) Models.
2002 Dodge Ram 1500, 2500 & 3500 Service Manual for: 3.7L 6 cyl. MPI Gasoline 3.7 L, 4.7L 8 cyl. MPI Gasoline 4.7 L, 5.7L 8 cyl. SMPI Gasoline 5.7 L, 5.9L 6 cyl. Turbo Diesel 5.9 L
5.9L 6 cyl. Turbo Diesel High Output 5.9 L, 8.0L 10 cyl. MPI Gasoline 8.0 L, 5.9L 8 cyl. SMPI Gasoline Light Duty 5.9 L Models
2003 Dodge Ram 1500, 2500 & 3500 Service : 3.7L 6 cyl. MPI Gasoline, 4.7L 8 cyl. MPI Gasoline, 5.7L 8 cyl. SMPI Gasoline, 5.9L 6 cyl. Turbo Diesel, 5.9L 6 cyl. Turbo Diesel High Output, 8.0L 10 cyl. MPI Gasoline, 5.9L 8 cyl. SMPI Gasoline Light Duty Models.
ENGINE - 3.7L
The 3.7 liter (226 CID) six-cylinder engine is an 90° single overhead camshaft engine (Fig. 1). The cast iron cylinder block is made up of two different components; the first component is the cylinder bore and upper block, the second component is the bedplate that comprises the lower portion of the cylinder block and houses the lower half of the crankshaft
main bearings. The cylinders are numbered from front to rear with the left bank being numbered 1,3, and 5 and the right bank being numbered 2,4, and 6.
The firing order is 1–6–5–4–3–2. The engine serial number is located at the right front side of the engine block.
ENGINE - 4.7L
DIAGNOSIS AND TESTING - CYLINDER COMPRESSION PRESSURE
The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes.
(1) Clean the spark plug recesses with compressed air.
(2) Remove the spark plugs.
(3) Secure the throttle in the wide-open position.
(4) Disable the fuel system (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - DESCRIPTION).
(5) Remove the ASD relay (Refer to 8 - ELECTRICAL/IGNITION CONTROL/AUTO SHUT DOWN RELAY - REMOVAL).
(6) Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions.
(7) Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders.
(8) (Refer to 9 - ENGINE - SPECIFICATIONS) for the correct engine compression pressures. For the rest of the procedures refer to the Factory Service manual at the top of the page.
ENGINE - 5.7L
The 5.7L engine (Fig. 1)(345 CID) eight-cylinder engine is a 90° V-Type lightweight, deep skirt cast iron block, aluminum heads, single cam, overhead valve engine with hydraulic roller tappets. The heads incorporate splayed valves with a hemispherical style combustion chamber and dual spark plugs. The cylinders are numbered from front to rear; 1, 3, 5, 7 on the left bank and 2, 4, 6, 8 on the right bank. The firing order is 1-8-4-3-6-5-7-2. Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine maintenance. These malfunctions may be classified as either performance (e.g., engine idles rough and stalls) or mechanical (e.g., a strange noise).
ENGINE OIL SPECIFICATION
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certified. MOPAR
t provides engine oils that conform to this service grade.
SAE VISCOSITY
An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 in the 5.7L engines. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation.
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals described in Maintenance Schedules(Refer to LUBRICATION & MAINTENANCE/MAINTENANCE
SCHEDULES - DESCRIPTION). Run engine until achieving normal operating temperature.
(1) Position the vehicle on a level surface and turn engine off.
(2) Hoist and support vehicle on safety stands.
(3) Remove oil fill cap.
(4) Place a suitable drain pan under crankcase drain.
(5) Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged.
(6) Install drain plug in crankcase. Torque to 34 N·m ( 25 ft. lbs.).
(7) Lower vehicle and fill crankcase with specified type and amount of engine oil described in this section. For the rest of the procedures refer to the Factory Service manual at the top of the page.
DESCRIPTION-5.9L Engine
The 5.9 Liter (360 CID) eight-cylinder engine is a V-Type lightweight, single cam, overhead valve engine with hydraulic roller tappets. This engine is designed for unleaded fuel. The engine lubrication system consists of a rotor type oil pump and a full flow oil filter. The cylinders are numbered from front to rear; 1, 3, 5, 7 on the left bank and 2, 4, 6, 8 on the right bank. The firing order is 1-8-4-3-6-5-7-2 (Fig. 1).
ENGINE 5.9L DIESEL
The cylinder block is constructed of cast iron. The casting is a skirted design which incorporates longitudal 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.
ENGINE 8.0L
The 8.0 Liter (488 CID) ten-cylinder engine is a V-Type lightweight, single cam, overhead valve engine with hydraulic roller tappets. This engine is designed for unleaded fuel. Engine lubrication system consists of a gerotor type oil pump mounted in the timing chain cover and driven by the crankshaft. The V-10 uses a full flow oil filter. The cylinders are numbered from front to rear; 1,3, 5, 7, 9 on the left bank and 2, 4, 6, 8, 10 on the right bank. The firing order is 1-10-9-4-3-6-5-8-7-2 (Fig. 1).
DIAGNOSIS AND TESTING—ENGINE DIAGNOSIS - PERFORMANCE
PERFORMANCE TROUBLESHOOTING CHART—GASOLINE ENGINES For the complete Factory Service Manual Troubleshooting chart & Repair Porcedures see manual link at the top of the page.
1. Weak or dead battery
1. Charge/Replace Battery. Check charging system. (Refer to 8 - ELECTRICAL/CHARGING - DIAGNOSIS AND TESTING).
2. Corroded or loose battery connections
2. Clean/tighten suspect battery/starter connections
3. Faulty starter or related circuit(s)
3. Check starting system. (Refer to 8 - ELECTRICAL/STARTING - DIAGNOSIS AND TESTING)
4. Seized accessory drive component
5. Remove accessory drive belt and attempt to start engine. If engine starts, repair/replace seized component.
5. Engine internal mechanical failure or hydro-static lock
6. Refer to (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
1. No spark 1. Check for spark.
2. No fuel 2. Perform fuel pressure test, and if necessary, inspect fuel injector(s) and driver circuits. (Refer to 14 - FUEL
3. Low or no engine compression 3. Perform cylinder compression pressure test. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING).
1. Worn or burned distributor rotor
2. Install new distributor rotor
3. Worn distributor shaft
4. Remove and repair distributor (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ DISTRIBUTOR - REMOVAL).
3. Worn or incorrect gapped spark plugs
3. Clean plugs and set gap.
4. Dirt or water in fuel system 4. Clean system and replace fuel filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing
7. Correct valve timing
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression
8. Test cylinder compression (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING).
9. Burned, warped, or pitted valves
9. Install/Reface valves as necessary
10. Plugged or restricted exhaust system
10. Install new parts as necessary
11. Faulty ignition cables 11. Replace any cracked or shorted cables
