Dodge Ram 3500 2003-2009 5.9L Engine Specifications
Explore the detailed 5.9L engine specifications for the 2003-2009 Dodge RAM 3500. Learn about horsepower, torque, fuel system, and more for maintenance, repair, and performance upgrades.
Overview Specifications
This document provides detailed specifications and technical information about the 5.9L engine used in the 2003-2009 Dodge RAM 3500. It is designed for mechanics, enthusiasts, and owners seeking in-depth knowledge about the engine's performance, design, and maintenance. Use the search functionality to locate specific details or navigate through sections to explore comprehensive information about the engine's features and capabilities.
How to Use
Use the search bar to enter keywords related to the 5.9L engine, such as 'torque,' 'horsepower,' or 'fuel system.' Results will highlight relevant sections and subsections for quick access.
Scroll through the document or use the table of contents to jump to specific sections. Each section is organized into subsections with detailed technical points for easy reference.
Key Specifications
Displacement
5.9L
Horsepower
325 HP
Torque
610 lb-ft
Fuel Type
Diesel
Cylinders
6
Available Specifications
Engine Performance
This section covers the performance metrics of the 5.9L engine, including horsepower, torque, and fuel efficiency. It also highlights the engine's capabilities under various driving conditions and loads.
Engine Performance
This section covers the performance metrics of the 5.9L engine, including horsepower, torque, and fuel efficiency. It also highlights the engine's capabilities under various driving conditions and loads.
Horsepower and Torque
- 325 horsepower at 2,900 RPM
- 610 lb-ft of torque at 1,600 RPM
- Optimized for heavy-duty towing and hauling
- Turbocharged for enhanced performance
Fuel Efficiency
- Average fuel economy of 14-18 MPG
- Common Rail Direct Injection (CRDI) system
- Designed for diesel fuel efficiency
- Emissions-compliant with EGR system
Engine Design
This section delves into the design and construction of the 5.9L engine, including its block, cylinder head, and cooling system. It also covers the materials and technologies used to ensure durability and reliability.
Engine Design
This section delves into the design and construction of the 5.9L engine, including its block, cylinder head, and cooling system. It also covers the materials and technologies used to ensure durability and reliability.
Block and Cylinder Head
- Cast-iron engine block for durability
- Aluminum cylinder head for weight reduction
- 6-cylinder inline configuration
- 24-valve design for improved airflow
Cooling System
- High-capacity radiator for efficient cooling
- Dual thermostats for optimal temperature control
- Heavy-duty water pump
- Auxiliary transmission cooler for towing
Maintenance and Service
This section provides guidance on maintaining and servicing the 5.9L engine, including recommended intervals for oil changes, filter replacements, and common troubleshooting tips.
Maintenance and Service
This section provides guidance on maintaining and servicing the 5.9L engine, including recommended intervals for oil changes, filter replacements, and common troubleshooting tips.
Oil and Filter Changes
- Recommended oil change interval: 7,500 miles
- Use of 15W-40 diesel engine oil
- High-capacity oil filter
- Regular inspection of oil levels
Common Issues and Solutions
- EGR valve clogging: Clean or replace as needed
- Turbocharger wear: Inspect and service regularly
- Fuel injector maintenance: Use quality diesel fuel
- Coolant leaks: Check hoses and gaskets
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Engine Specifications
Overview
- Type
- Turbocharged Inline-6 Diesel
- Configuration
- OHV, 24-valve
- Platform
- Cummins ISB 5.9L
- Material
- Cast Iron Block and Head
- Location
- Front Longitudinal
- Displacement
- 5.9 liters (359 cubic inches)
Dimensions
- Length
- 37.5 inches (952.5 mm)
- Width
- 28.3 inches (718.8 mm)
- Height
- 35.2 inches (894.1 mm)
- Weight
- 1100 lbs (499 kg)
- Bore
- 4.02 inches (102.1 mm)
- Stroke
- 4.72 inches (119.9 mm)
- Oil Capacity
- 12 quarts (11.4 liters)
- Coolant Capacity
- 6.5 gallons (24.6 liters)
Materials
- Block
- Cast Iron
- Cylinder Head
- Cast Iron
- Pistons
- Aluminum Alloy
- Crankshaft
- Forged Steel
- Valves
- Stainless Steel
Features
- Fuel System
-
- High-Pressure Common Rail Injection
- Electronic Control Module (ECM)
- Turbocharger with Wastegate
- Intercooler
- Cooling System
-
- Dual Thermostats
- High-Capacity Radiator
- Coolant Bypass System
- Electric Cooling Fan
- Lubrication System
-
- Gear-Driven Oil Pump
- Full-Flow Oil Filter
- Oil Cooler
- High-Capacity Oil Pan
- Emissions Control
-
- Exhaust Gas Recirculation (EGR)
- Diesel Particulate Filter (DPF)
- Selective Catalytic Reduction (SCR)
- Oxidation Catalyst
- Performance Features
-
- Variable Geometry Turbocharger (VGT)
- High Torque Output
- Low-End Power Delivery
- Durable Design for Heavy-Duty Use
Safety Features
- Engine Protection
-
- Overheat Shutdown
- Low Oil Pressure Warning
- Overboost Protection
- Emissions Safety
-
- DPF Regeneration Monitoring
- EGR System Diagnostics
- Exhaust Temperature Sensors
- Electrical Safety
-
- Waterproof ECM
- Short Circuit Protection
- Ground Fault Detection
Comfort Features
- Noise Reduction
-
- Sound Dampening Materials
- Balanced Rotating Assembly
- Quiet Turbocharger Design
- Vibration Control
-
- Hydraulic Engine Mounts
- Balanced Crankshaft
- Dual-Mass Flywheel
- Climate Control
-
- Heated Fuel Filter
- Cold Weather Starting Aid
- Integrated Coolant Heater
Accessories
- Engine Bay
-
- Air Intake System
- Turbocharger Assembly
- Intercooler Piping
- Electrical
-
- Alternator
- Starter Motor
- Glow Plug Controller
- Cooling
-
- Radiator
- Coolant Reservoir
- Electric Fan Assembly
Maintenance
- Service interval
- Every 7,500 miles or 6 months
- Service Items
-
- Oil and Filter Change
- Fuel Filter Replacement
- Air Filter Inspection
- Coolant Level Check
- Belt Tension Inspection
- EGR System Cleaning
- Maintenance Notes
- Use only recommended fluids and filters. Follow severe duty schedule for heavy towing or extreme conditions.
Warranty
- Basic Warranty
- Miles: 100,000Years: 5Coverage: Bumper-to-Bumper
- Powertrain Warranty
- Miles: 200,000Years: 10Coverage: Engine, Transmission, Drivetrain
- Emissions Warranty
- Miles: 150,000Years: 8Coverage: Catalytic Converter, DPF, EGR System
- Corrosion Warranty
- Miles: UnlimitedYears: 10Coverage: Perforation from Rust
Production Details
- Manufacturer
- Cummins Inc.
- Manufacturing Process
-
- Precision Casting for Block and Head
- CNC Machining for Critical Components
- Robotic Assembly for Consistency
- Dynamometer Testing for Performance
- Quality Control
- inspection Stages: Raw Material Testing, Dimensional Accuracy Checks, Pressure Testing for Cooling System, Final Performance VerificationCertifications: ISO 9001, EPA Emissions Compliance, DOT Safety Standards
- Sustainability Practices
-
- Recycled Materials in Casting
- Energy-Efficient Manufacturing
- Waste Reduction Programs
- Low-Emission Production Facilities
- Production Metrics
- Annual Output: 250,000 unitsDefect Rate: Less than 0.1%Lead Time: 4-6 weeks
Service Information for 5.9l engine Service
Maintenance and service requirements specific to this component
- Oil and Filter Change
- Fuel Filter Replacement
- Air Filter Inspection
- Coolant Level Check
- Belt Tension Inspection
Use synthetic oil for improved performance and longevity.
- EGR System Cleaning
- Turbocharger Inspection
- Coolant Flush and Replacement
- Glow Plug Testing
- Battery Load Test
Inspect for leaks and wear in high-stress areas.
- Timing Belt Replacement
- Water Pump Replacement
- Injector Cleaning
- Transmission Fluid Change
- Differential Fluid Change
Major service interval requires specialized tools and expertise.
Common Questions
Find answers to common questions about torque specifications
Q1 Is the 5.9L engine compatible with other Dodge RAM models?
Is the 5.9L engine compatible with other Dodge RAM models?
The 5.9L Cummins diesel engine, used in the 2003-2009 Dodge RAM 3500, is specifically designed for heavy-duty applications. While it shares similarities with other Cummins engines, compatibility with other RAM models depends on the year and configuration. Always verify engine mounts, transmission compatibility, and ECU requirements before attempting cross-model installations.
Q2 What are the maintenance requirements for the 5.9L engine?
What are the maintenance requirements for the 5.9L engine?
The 5.9L engine requires regular maintenance to ensure longevity. Key tasks include oil changes every 7,500 miles, fuel filter replacement every 15,000 miles, and air filter checks every 30,000 miles. Inspect the cooling system, belts, and hoses annually. Use high-quality diesel fuel and additives to prevent injector issues. Follow the manufacturer's service schedule for optimal performance.
Q3 How do I replace the 5.9L engine in a Dodge RAM 3500?
How do I replace the 5.9L engine in a Dodge RAM 3500?
Replacing the 5.9L engine involves several steps: disconnect the battery, drain fluids, and remove the hood, radiator, and accessories. Unbolt the transmission and engine mounts, then lift the engine out using a hoist. Install the new engine by reversing the process, ensuring proper alignment and torque specifications. Refer to the service manual for detailed instructions and safety precautions.
Q4 What are common troubleshooting steps for the 5.9L engine?
What are common troubleshooting steps for the 5.9L engine?
Common issues include hard starts, loss of power, and excessive smoke. Start by checking the fuel system for clogs or air leaks. Inspect the turbocharger for boost pressure and the injectors for proper operation. Use a diagnostic scanner to check for error codes. Regularly clean the EGR valve and inspect the exhaust system for blockages.
Q5 How can I optimize the performance of the 5.9L engine?
How can I optimize the performance of the 5.9L engine?
To optimize performance, consider upgrading the air intake and exhaust systems for better airflow. Use a performance tuner to adjust fuel mapping and boost pressure. Regularly clean the fuel injectors and replace worn components. Ensure proper tire pressure and alignment for improved efficiency. Avoid overloading the vehicle to reduce strain on the engine.
Factory Service Resources
Access official service manuals, technical documents, and repair guides. These resources provide detailed procedures, specifications, and diagrams directly from the manufacturer.
2003-2009 Dodge RAM 3500 Service Manual
Coming SoonComprehensive guide covering maintenance, repair, and troubleshooting for the 5.9L engine and related systems.
Technical Service Bulletin: 5.9L Engine Updates
Coming SoonDetails updates and fixes for common issues in the 5.9L engine, including software updates and part replacements.
5.9L Engine Parts and Accessories Catalog
Coming SoonCatalog listing OEM and aftermarket parts for the 5.9L engine, including filters, gaskets, and performance upgrades.
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Technical Information
- All specifications, including torque values, fluid capacities, and maintenance procedures, should be verified against your vehicle's factory service manual.
- Vehicle specifications and procedures may vary by model year, trim level, and region.
- Always follow the manufacturer's recommended procedures and safety precautions.
- Working on vehicles can be dangerous. Always take proper safety precautions and use appropriate safety equipment.
- If you're unsure about any procedure, consult a qualified professional mechanic.
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