2003 Dodge Ram Van (1500) Service & Repair Manual

3.9L V6 - VIN [X] ENGINES Chrysler Corp. 3.9L V6 - VIN [X] ENGINE IDENTIFICATION ** PLEASE READ THIS FIRST ** 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  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  Letter "A" following engine serial number indicates .020" (.51 mm) oversize cylinder bores.  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.  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. ADJUSTMENTS VALVE CLEARANCE ADJUSTMENT Hydraulic valve lifters are used. No valve adjustment is required. NOTE: For repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in GENERAL INFORMATION. Engine Code 3.9L PFI X Monday, December 04, 2017 11:38:56 PM Page 1 © 2011 Mitchell Repair Information Company, LLC.

REMOVAL & INSTALLATION 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. ENGINE Removal (Ram Van/Wagon) 1. Release fuel pressure. See 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 battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. 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. CAUTION: Fuel system is under pressure. Pressure must be released before servicing fuel system components. CAUTION: When removing engine, DO NOT lift engine by intake manifold. Monday, December 04, 2017 11:38:39 PM Page 2 © 2011 Mitchell Repair Information Company, LLC.

5. Remove intake manifold. See INTAKE MANIFOLD . 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 . 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. 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. 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. See Fig. 1 . Remove engine from vehicle. CAUTION: When removing engine, DO NOT lift engine by intake manifold. NOTE: It may be necessary to remove manual transmission if transmission cannot be supported using floor jack. NOTE: On Dakota 4WD models, the engine, transmission and front axle are connected and supported with insulators and brackets. Monday, December 04, 2017 11:38:39 PM Page 3 © 2011 Mitchell Repair Information Company, LLC.

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. Monday, December 04, 2017 11:38:39 PM Page 4 © 2011 Mitchell Repair Information Company, LLC.

Fig. 1: Dakota Engine Mounts Courtesy of CHRYSLER CORP. INTAKE MANIFOLD Removal 1. Release fuel pressure. See 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). Monday, December 04, 2017 11:38:39 PM Page 5 © 2011 Mitchell Repair Information Company, LLC.

Fig. 2: Plenum Pan Bolt Tightening Sequence Courtesy of CHRYSLER CORP. Installation 1. Install plenum pan and install all bolts finger tight. Tighten bolts to specification, in steps, and in sequence. See Fig. 2 . See TORQUE SPECIFICATIONS . 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. See Fig. 3 . See TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedure. Fig. 3: Intake Manifold Bolt Tightening Sequence Monday, December 04, 2017 11:38:39 PM Page 6 © 2011 Mitchell Repair Information Company, LLC.

Courtesy of CHRYSLER CORP. EXHAUST MANIFOLD Removal 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. Installation 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. CYLINDER HEAD Removal 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 and EXHAUST MANIFOLD. 2. Remove rocker arms and push rods. See ROCKER ARMS . Remove cylinder head bolts, cylinder head and gasket. Inspection Check cylinder head warpage. Repair or replace cylinder head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Installation To install, reverse removal procedure. Tighten cylinder head bolts to specification and in sequence using 3 steps. See Fig. 4 . See TORQUE SPECIFICATIONS . CAUTION: Install NEW studs in cylinder head if studs came out when removing exhaust manifold. Apply sealant to coarse threads of studs before installing in head. Monday, December 04, 2017 11:38:39 PM Page 7 © 2011 Mitchell Repair Information Company, LLC.

Fig. 4: Cylinder Head Bolt Tightening Sequence Courtesy of CHRYSLER CORP. FRONT COVER OIL SEAL Removal 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. Installation 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. FRONT COVER Monday, December 04, 2017 11:38:39 PM Page 8 © 2011 Mitchell Repair Information Company, LLC.

Removal 1. Disconnect battery. Drain coolant. Remove power steering pump (if equipped). Remove water pump. See 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. Installation 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 . Tighten front cover, oil pan and then vibration damper bolts to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure. TIMING CHAIN Inspection 1. Remove front cover. See FRONT COVER . 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. Removal Rotate crankshaft so timing marks are aligned. See Fig. 5 . Remove camshaft sprocket bolt, camshaft sprocket, timing chain and crankshaft sprocket. Installation 1. Install timing chain and sprockets. Ensure timing marks are aligned. See Fig. 5 . Install camshaft sprocket bolt and tighten to specification. See TORQUE SPECIFICATIONS . 2. Ensure camshaft end play is within specification. See CAMSHAFT 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. NOTE: When applying torque to camshaft sprocket bolt, DO NOT allow crankshaft to move. It may be necessary to hold crankshaft. Monday, December 04, 2017 11:38:39 PM Page 9 © 2011 Mitchell Repair Information Company, LLC.

Fig. 5: Aligning Timing Marks Courtesy of CHRYSLER CORP. ROCKER ARMS Removal 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). Installation 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). VALVE LIFTERS CAUTION: To avoid piston-to-valve contact during rocker arm installation, crankshaft MUST be placed in specified position. Wait 5 minutes before starting engine to allow valve lifters to bleed down after rocker arm installation. Monday, December 04, 2017 11:38:39 PM Page 10 © 2011 Mitchell Repair Information Company, LLC.

2003 Dodge Ram Van (1500) Service & Repair Manual

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