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(9) Install the front crossmember(Refer to 13 - FRAME & BUMPERS/FRAME/FRONT CROSS- MEMBER - INSTALLATION).
(10) Fill engine oil. (11) Reconnect the negative battery cable. (12) Start engine and check for leaks.
9 - 218
ENGINE - 5.7L
OIL PUMP REMOVAL
DR
(1) Remove the oil pan and pick-up tube(Refer to 9
- ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(2) Remove the timing chain cover(Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
(3) Remove the four bolts, and the oil pump.
CLEANING
(1) Wash all parts in a suitable solvent.
INSPECTION
CAUTION: Oil pump pressure relief valve and spring should not be removed from the oil pump. If these are disassembled and or removed from the pump the entire oil pump assem- bly must be replaced.
components
(1) Remove the pump cover. (2) Clean all parts thoroughly. Mating surface of the oil pump housing should be smooth. If the pump cover is scratched or grooved the oil pump assembly should be replaced.
(3) Slide outer rotor into the body of the oil pump. Press the outer rotor to one side of the oil pump body and measure clearance between the outer rotor and the body (Fig. 28). If the measurement is 0.235mm (0.009 in.) or more the oil pump assembly must be replaced.
(4) Install the inner rotor in the into the oil pump body. Measure the clearance between the inner and outer rotors (Fig. 29). If the clearance between the rotors is .150 mm (0.006 in.) or more the oil pump assembly must be replaced.
(5) Place a straight edge across the body of the oil pump (between the bolt holes), if a feeler gauge of .095 mm (0.0038 in.) or greater can be inserted between the straightedge and the rotors, the pump must be replaced (Fig. 30).
(6) Reinstall the pump cover. Torque fasteners to
15 N·m (132 in. lbs.).
NOTE: The 5.7 Oil pump is released as an assem- bly. There are no DaimlerChrysler part numbers for Sub-Assembly components. the oil pump is not functioning or out of specification it must be replaced as an assembly.
In the event
Fig.28MeasuringOuterRotorClearance
1 - FEELER GAUGE 2 - OUTER ROTOR
Fig.29MeasuringClearanceBetweenRotors-
Typical
1 - OUTER ROTOR 2 - FEELER GAUGE 3 - INNER ROTOR
DR OIL PUMP (Continued)
ENGINE - 5.7L
9 - 219
(2) Spray a small stream of water at the suspected
leak area.
(3) If a change in RPM is observed the area of the
suspected leak has been found.
(4) Repair as required.
REMOVAL
ing components:
(1) Disconnect negative cable from battery. (2) Remove resonator assembly and air inlet hose. (3) Disconnect electrical connectors for the follow- † Manifold Absolute Pressure (MAP) Sensor † Intake Air Temperature (IAT) Sensor † Throttle Position (TPS) Sensor † Coolant Temperature (CTS) Sensor (4) Disconnect brake booster hose and positive
crankcase ventilation (PCV) hose.
(5) Remove generator and set aside.
NOTE: remove freon from A/C compressor.
is not necessary to remove lines or
It
(6) Remove air conditioning compressor and set
aside..
(7) Bleed fuel system (Refer to 14 - FUEL SYS- TEM/FUEL DELIVERY - STANDARD PROCE- DURE).
(8) Remove intake manifold retaining fasteners in a crisscross pattern starting from the outside bolts and ending at the middle bolts.
(9) Remove intake manifold and IAFM as an
assembly.
Fig.30MeasuringClearanceOverRotors-Typical 1 - STRAIGHT EDGE 2 - FEELER GAUGE
INSTALLATION
(1) Position the oil pump onto the crankshaft and
install the 4 oil pump retaining bolts.
(2) Tighten the oil pump retaining bolts to 28 N·m
(250 in. lbs.).
(3) Install the timing chain cover(Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
(4) Install the pick-up tube and oil pan(Refer to 9 - INSTALLA-
ENGINE/LUBRICATION/OIL PAN - TION).
INTAKE MANIFOLD DESCRIPTION
The intake manifold is made of a composite mate- rial and features long runners which maximizes low end torque. The intake manifold uses single plane sealing which consist of eight individual press in place port gaskets to prevent leaks.
DIAGNOSIS AND TESTING - INTAKE MANIFOLD LEAKAGE
An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
CLEANING
NOTE: There is NO approved repair procedure for the intake manifold. If severe damage is found dur- ing inspection, the intake manifold must be replaced.
Before installing the intake manifold thoroughly clean the mating surfaces. Use a suitable cleaning solvent, then air dry.
INSPECTION
(1) Inspect the intake sealing surface for cracks,
nicks and distortion.
(2) Inspect the intake manifold vacuum hose fit-
tings for looseness or blockage.
(3) Inspect the manifold to throttle body mating
surface for cracks, nicks and distortion.
INSTALLATION
(1) Install intake manifold seals. (2) Position intake manifold and IAFM. (3) Install
intake manifold retaining bolts, and tighten in sequence from the middle bolts towards
ENGINE - 5.7L
9 - 220
INTAKE MANIFOLD (Continued)the outside in a crisscross pattern. Torque fasteners to 12 N·m (105 in. lbs.).
(4) Connect electrical connectors for the following components: † Manifold Absolute Pressure (MAP) Sensor † Intake Air Temperature (IAT) Sensor † Throttle Position (TPS) Sensor † Coolant Temperature (CTS) Sensor † Idle Air Control (IAC) Motor (5) Install generator. (6) Install A/C compressor. (7) Connect Brake booster hose and Positive crank-
case ventilation (PCV) hose.
(8) Install resonator assembly and air inlet hose. (9) Connect negative cable to battery.
EXHAUST MANIFOLD DESCRIPTION
The exhaust manifolds are log style with a pat- ented flow enhancing design to maximize perfor- mance. The exhaust manifolds are made of high silicon molybdenum cast iron. A perforated core graphite exhaust manifold gasket is used to improve sealing to the cylinder head. The exhaust manifolds are covered by a three layer laminated heat shield for thermal protection and noise reduction. The heat shields are fastened with a torque prevailing nut that is backed off slightly to allow for the thermal expansion of the exhaust manifold.
OPERATION
The exhaust manifolds collect the engine exhaust exiting the combustion chambers, then channels the exhaust gases to the exhaust pipes attached to the manifolds.
REMOVAL
EXHAUST MANIFOLD
(1) Disconnect negative battery cable. (2) Raise vehicle. (3) Remove exhaust pipe to manifold bolts. (4) Lower vehicle. (5) Install engine support
fixture special
tool
#8534.
(6) Raise engine enough to remove manifolds.
CAUTION: Do not damage engine harness while raising the engine.
(7) Remove heat shield. (8) Remove manifold bolts. (9) Remove manifold and gasket.
DR
CLEANING
Clean mating surfaces on cylinder head and mani- fold. Wash with solvent and blow dry with com- pressed air.
INSPECTION
Inspect manifold for cracks. Inspect mating surfaces of manifold for flatness with a straight edge. Gasket surfaces must be flat within 0.2 mm per 300 mm (0.008 inch per foot).
INSTALLATION
EXHAUST MANIFOLD
(1) Install manifold gasket and manifold. (2) Install manifold bolts and tighten to 25 N·m
(3) Install heat shield and tighten nuts to 15 N·m
(18 ft. lbs.).
(11 ft. lbs.).
(4) Lower engine.
CAUTION: Do not damage engine harness while lowering the engine.
(5) Remove engine support fixture from engine. (6) Raise vehicle. (7) Tighten right and left side engine mount
through bolts.
(8) Install exhaust flange to pipe bolts. (9) Lower vehicle. (10) Connect negative battery cable.
TIMING/CHAIN COVER REMOVAL
(1) Disconnect the battery negative cable. (2) Remove air cleaner assembly. (3) Drain cooling system. (4) Remove accessory drive belt. (5) Remove fan and fan drive assembly (Refer to 7
VISCOUSCOOLING/ENGINE/FAN
DRIVE
CLUTCH - REMOVAL).
(6) Remove coolant bottle and washer bottle. (7) Remove fan shroud.
NOTE: It is not necessary to disconnect A/C lines or discharge freon.
(8) Remove A/C compressor and set aside. (9) Remove the generator. (10) Remove upper radiator hose. (11) Disconnect both heater hoses at timing cover. (12) Disconnect lower radiator hose at engine. (13) Remove accessory drive belt tensioner and
both idler pulleys.
DR TIMING/CHAIN COVER (Continued)
(14) Remove
to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL).
crankshaft damper(Refer
NOTE: Do not remove the hoses from the power steering pump.
(15) Remove power steering pump and set aside. (16) Remove the dipstick support bolt. (17) Drain the engine oil. (18) Remove the oil pan and pick up tube(Refer to 9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL).
NOTE: It is not necessary to remove water pump for timing cover removal.
(19) Remove timing cover bolts and remove cover.
INSTALLATION
(1) Clean timing chain cover and block surface.
NOTE: Always install a new gasket on timing cover.
(2) Install cover and new gasket. Tighten fasteners
to 28 N·m (250 in. lbs.).
NOTE: The large lifting stud is torqued to 55 N·m (40 ft. lbs.).
(3) Install the oil pan and pick up tube(Refer to 9 - INSTALLA-
ENGINE/LUBRICATION/OIL PAN - TION).
(4) Install the A/C compressor. (5) Install the generator. (6) Install power steering pump. (7) Install the dipstick support bolt. (8) Install the thermostat housing. (9) Install
crankshaft
ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).
damper(Refer
to
(10) Install accessory drive belt tensioner assembly
and both idler pulleys.
(11) Install radiator lower hose. (12) Install both heater hoses. (13) Install radiator fan shroud. (14) Install the fan and fan drive assembly (15) Install the accessory drive belt. (16) Install the coolant bottle and washer bottle. (17) Install the upper radiator hose. (18) Install the air cleaner assembly. (19) Fill cooling system. (20) Refill engine oil. (21) Connect the battery negative cable.
ENGINE - 5.7L
9 - 221
TIMING/CHAIN AND SPROCKETS REMOVAL
(1) Disconnect battery negative cable. (2) Drain cooling system. (3) Remove Timing Chain Cover.
CAUTION: The camshaft pin and the slot in the cam sprocket must be clocked at 12:00. The crankshaft keyway must be clocked at 2:00. The crankshaft sprocket must be installed so that the dots and or paint marking is at 6:00.
(4) Re-install
the vibration damper bolt
finger tight. Using a suitable socket and breaker bar, rotate the crankshaft to align timing chain sprockets and keyways as shown (Fig. 31).
Fig.315.7LTIMINGMARKALIGNMENT
1 - Chain Tensioner 2 - Camshaft Sprocket 3 - Crankshaft Sprocket
(5) Retract tensioner shoe until hole in shoe lines up with hole in bracket. Slide a suitable pin into the holes.
(6) Remove camshaft sprocket attaching bolt and remove timing chain with crankshaft and camshaft sprockets.
(7) If tensioner assembly is to be replaced, remove the tensioner to block bolts and remove tensioner assembly.
DR
(6) Slide both sprockets evenly over their respec-
tive shafts and check alignment of timing marks.
(7) Install the camshaft bolt. Tighten the bolt to
122 N·m (90 ft. lbs.) torque.
(8) Remove tensioner pin. Again, verify align-
ment of timing marks.
(9) Install the oil pump(Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(10) Install the oil pan and pick up(Refer to 9 - INSTALLA-
ENGINE/LUBRICATION/OIL PAN - TION).
(11) Install the timing chain cover(Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
(12) Fill cooling system(Refer to 7 - COOLING -
STANDARD PROCEDURE).
(13) Connect battery negative cable. (14) Start engine and check for oil and coolant
leaks.
TIMING CHAIN/TENSIONER DESCRIPTION
The timing chain tensioner is a stamped steel con- stant tension mechanical design. It is mounted to the front of the engine, behind the timing chain drive.
OPERATION
The timing chain tension is maintained by routing the timing chain through the tensioner assembly. A nylon covered spring steel arm presses on the timing chain maintaining the correct chain tension.
ENGINE - 5.7L
9 - 222
TIMING/CHAIN AND SPROCKETS (Continued) INSTALLATION(1) If tensioner assembly is being replaced, install tensioner and mounting bolts. Torque bolts to 28 N·m (250 in. lbs.).
(2) Retract tensioner if required.
CAUTION: The camshaft pin and the slot in the cam sprocket must be clocked at 12:00. The crankshaft keyway must be clocked at 2:00. The crankshaft sprocket must be installed so that the dots and or paint marking is at 6:00.
(3) Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores (Fig. 32).
CAUTION: The timing chain must be installed with the single plated link aligned with the dot and or paint marking on the camshaft sprocket. The crank- shaft sprocket is aligned with the dot and or paint marking on the sprocket between two plated timing chain links.
(4) Place timing chain around both sprockets (Fig.
32).
(5) Lift sprockets and chain (keep sprockets tight
against the chain in position as shown).
Fig.325.7LTIMINGMARKALIGNMENT
1 - Chain Tensioner 2 - Camshaft Sprocket 3 - Crankshaft Sprocket
DR
ENGINE - 5.9L
9 - 223
ENGINE - 5.9L
TABLE OF CONTENTS
page
page
ENGINE - 5.9L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 224
DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION . . . . . . . . . . 225
DIAGNOSIS AND TESTING—ENGINE
DIAGNOSIS - PERFORMANCE . . . . . . . . . . 226
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL . . . . . . . . . . . . 228
DIAGNOSIS AND TESTING—ENGINE
DIAGNOSIS - LUBRICATION . . . . . . . . . . . . 230
DIAGNOSIS AND TESTING—CYLINDER
COMPRESSION PRESSURE . . . . . . . . . . . . 231
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE . . . . . 231
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS . . . . . . . . 232
STANDARD PROCEDURE - REPAIR
CYLINDER HEAD COVER(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 245
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 245INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 246
STANDARD PROCEDURE—VALVES, GUIDESAND SPRINGS . . . . . . . . . . . . . . . . . . . . . . . 246
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 248
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 248ROCKER ARM / ADJUSTER ASSEMBLY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 249ENGINE BLOCK
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 249DAMAGED OR WORN THREADS . . . . . . . . 232
CAMSHAFT & BEARINGS (IN BLOCK)
STANDARD PROCEDURE—HYDROSTATIC
LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
STANDARD PROCEDURE - CYLINDER
BORE HONING . . . . . . . . . . . . . . . . . . . . . . 233
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 234
SPECIFICATIONS5.9L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 235
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . 239SPECIAL TOOLS
REMOVAL—CAMSHAFT . . . . . . . . . . . . . . . . . 250
INSTALLATION—CAMSHAFT . . . . . . . . . . . . . 250
CONNECTING ROD BEARINGSSTANDARD PROCEDURE - CONNECTING
ROD BEARING FITTING . . . . . . . . . . . . . . . 251
CRANKSHAFT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 252
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 252
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 2525.9L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 240
CRANKSHAFT MAIN BEARINGS
AIR CLEANER ELEMENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 242CYLINDER HEAD DESCRIPTION
DESCRIPTION—CYLINDER HEAD DESCRIPTION - CYLINDER HEAD COVER
. . . . . . . 243
GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
OPERATION
OPERATION—CYLINDER HEAD . . . . . . . . . 243
OPERATION - CYLINDER HEAD COVERGASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
DIAGNOSIS AND TESTING—CYLINDER HEAD
GASKET FAILURE . . . . . . . . . . . . . . . . . . . . 243
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 244
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 244DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 253
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 253
STANDARD PROCEDURE—CRANKSHAFTMAIN BEARING FITTING . . . . . . . . . . . . . . . 253
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 254CRANKSHAFT OIL SEAL - FRONT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 254
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 254
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 255CRANKSHAFT OIL SEAL - REAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 255
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 255
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 256DISTRIBUTOR BUSHING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 2589 - 224
ENGINE - 5.9L
DR
HYDRAULIC LIFTERS
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 270
DIAGNOSIS AND TESTING—HYDRAULIC
TAPPETS . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 260OIL PAN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 271
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 271PISTON & CONNECTING ROD
OIL PUMP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 260
STANDARD PROCEDURE - PISTON FITTING . 260
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 261
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 261PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 263FRONT MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 265REAR MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 267LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 267
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 267
DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING—ENGINE OIL
LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
DIAGNOSIS AND TESTING—ENGINE OIL
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 269
OIL
STANDARD PROCEDURE - ENGINE OIL
. . . . 269
OIL FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
ENGINE - 5.9L DESCRIPTION
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 272
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 272
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 274INTAKE MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 274
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 274
DIAGNOSIS AND TESTING—INTAKEMANIFOLD LEAKAGE
. . . . . . . . . . . . . . . . . 274
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 275
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 275EXHAUST MANIFOLD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 277
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 277
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 277
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 277TIMING BELT / CHAIN COVER(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 278TIMING BELT/CHAIN AND SPROCKETS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
INSPECTION—MEASURING TIMING CHAINSTRETCH
. . . . . . . . . . . . . . . . . . . . . . . . . . 279
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 279The 5.9 Liter (360 CID) eight-cylinder engine is a single cam, overhead valve V-Type lightweight, 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).
Fig.1FiringOrder
ENGINE - 5.9L
9 - 225
These malfunctions may be classified as either mechanical (e.g., a strange noise), or performance (e.g., engine idles rough and stalls).
(Refer to 9 - ENGINE - DIAGNOSIS AND TEST- ING - Preformance) or (Refer to 9 - ENGINE - DIAG- NOSIS AND TESTING - Mechanical). Refer to 14 - FUEL SYSTEM for fuel system diagnosis.
ENGINE - DIAGNOSIS AND TESTING)
Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can- not be isolated with the Service Diagnosis charts. Information concerning additional tests and diagno- sis is provided within the following: † Cylinder Compression Pressure Test (Refer to 9 - † Cylinder Combustion Pressure Leakage Test (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING) † Cylinder Head Gasket Failure Diagnosis (Refer to 9 - ENGINE/CYLINDER HEAD - DIAGNOSIS AND TESTING) † Intake Manifold Leakage Diagnosis (Refer to 9 - † Lash Adjuster (Tappet) Noise Diagnosis (Refer to 9 - ENGINE/ENGINE BLOCK/HYDRAULIC LIFT- ERS (CAM IN BLOCK) - DIAGNOSIS AND TEST- ING)† Engine Oil Leak Inspection (Refer to 9 - ENGINE/LUBRICATION - DIAGNOSIS AND TEST- ING)
ENGINE/MANIFOLDS/INTAKE DIAGNOSIS AND TESTING)
MANIFOLD
DR ENGINE - 5.9L (Continued)
The engine serial number is stamped into a machined pad located on the left, front corner of the cylinder block. When component part replacement is necessary, use the engine type and serial number for reference (Fig. 2).
Fig.2EngineIdentificationNumber
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION Engine diagnosis is helpful
in determining the causes of malfunctions not detected and remedied by routine maintenance.
ENGINE - 5.9L
9 - 226
ENGINE - 5.9L (Continued) DIAGNOSIS AND TESTING—ENGINE DIAGNOSIS - PERFORMANCEPERFORMANCE DIAGNOSIS CHART—GASOLINE ENGINES
DR
CONDITION
POSSIBLE CAUSES
CORRECTION
ENGINE WILL NOT CRANK
1. Weak or dead battery
2. Corroded or loose battery connections
3. Faulty starter or related circuit(s)
4. Seized accessory drive component
5. Engine internal mechanical failure or hydro-static lock
ENGINE CRANKS BUT WILL NOT START
1. No spark
2. No fuel
3. Low or no engine compression
ENGINE LOSS OF POWER
1. Worn or burned distributor rotor 2. Worn distributor shaft
3. Worn or incorrect gapped spark plugs
4. Dirt or water in fuel system 5. Faulty fuel pump 6. Incorrect valve timing 7. Blown cylinder head gasket 8. Low compression
9. Burned, warped, or pitted valves 10. Plugged or restricted exhaust system 11. Faulty ignition cables
1. Charge/Replace Battery. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/ BATTERY - STANDARD PROCEDURE). Check charging system. (Refer to 8 - ELECTRICAL/CHARGING - DIAGNOSIS AND TESTING).
2. Clean/tighten suspect battery/starter connections 3. Check starting system. (Refer to 8 - ELECTRICAL/STARTING - DIAGNOSIS AND TESTING) 4. Remove accessory drive belt and attempt to start engine. If engine starts, repair/replace seized component. 5. Refer to (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
1. Check for spark. (Refer to 8 - ELECTRICAL/IGNITION CONTROL - DESCRIPTION)
2. Perform fuel pressure test, and if necessary, inspect fuel injector(s) and driver circuits. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP - DIAGNOSIS AND TESTING). 3. Perform cylinder compression pressure test. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING).
1. Install new distributor rotor 2. Remove and repair distributor (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ DISTRIBUTOR - REMOVAL). 3. Clean plugs and set gap. (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ SPARK PLUG - CLEANING). 4. Clean system and replace fuel filter 5. Install new fuel pump 6. Correct valve timing 7. Install new cylinder head gasket 8. Test cylinder compression (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING). 9. Install/Reface valves as necessary 10. Install new parts as necessary 11. Replace any cracked or shorted cables
DR ENGINE - 5.9L (Continued)
ENGINE - 5.9L
9 - 227
CONDITION
POSSIBLE CAUSES
CORRECTION
12. Faulty ignition coil
ENGINE STALLS OR ROUGH IDLE
1. Carbon build-up on throttle plate
2. Engine idle speed too low
3. Worn or incorrectly gapped spark plugs
4. Worn or burned distributor rotor 5. Spark plug cables defective or crossed
6. Faulty coil
7. Intake manifold vacuum leak
ENGINE MISSES ON ACCELERATION
1. Worn or incorrectly gapped spark plugs
2. Spark plug cables defective or crossed
3. Dirt in fuel system 4. Burned, warped or pitted valves 5. Faulty coil
12. Test and replace, as necessary (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ IGNITION COIL - REMOVAL).
1. Remove throttle body and de-carbon. (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/THROTTLE BODY - REMOVAL). 2. Check Idle Air Control circuit. (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/ IDLE AIR CONTROL MOTOR - DESCRIPTION) 3. Replace or clean and re-gap spark plugs (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG - CLEANING) 4. Install new distributor rotor 5. Check for correct firing order or replace spark plug cables. (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ SPARK PLUG CABLE - DIAGNOSIS AND TESTING) 6. Test and replace, if necessary (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ IGNITION COIL - REMOVAL) 7. Inspect intake manifold gasket and vacuum hoses (Refer to 9 - ENGINE/ MANIFOLDS/INTAKE MANIFOLD - DIAGNOSIS AND TESTING).
1. Replace spark plugs or clean and set gap. (Refer to 8 - ELECTRICAL/IGNITION CONTROL/SPARK PLUG - CLEANING) 2. Replace or rewire secondary ignition cables. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG CABLE - REMOVAL) 3. Clean fuel system 4. Install new valves 5. Test and replace as necessary (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ IGNITION COIL - REMOVAL)
ENGINE - 5.9L
9 - 228
ENGINE - 5.9L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICALENGINE MECHANICAL DIAGNOSIS CHART
DR
CONDITION
POSSIBLE CAUSES
CORRECTION
NOISY VALVES/LIFTERS
1. High or low oil level in crankcase
2. Thin or diluted oil
3. Low oil pressure
4. Dirt in tappets/lash adjusters
5. Bent push rod(s) 6. Worn rocker arms
7. Worn tappets/lash adjusters
8. Worn valve guides
9. Excessive runout of valve seats or valve faces
1. Insufficient oil supply 2. Low oil pressure
3. Thin or diluted oil
4. Excessive connecting rod bearing clearance
5. Connecting rod journal out of round 6. Misaligned connecting rods
1. Insufficient oil supply 2. Low oil pressure
3. Thin or diluted oil
CONNECTING ROD NOISE
MAIN BEARING NOISE
1. Check for correct oil level. Adjust oil level by draining or adding as needed 2. Change oil. (Refer to 9 - ENGINE/ LUBRICATION/OIL - STANDARD PROCEDURE) 3. Check engine oil level. If ok, Perform oil pressure test. (Refer to 9 - ENGINE/LUBRICATION - DIAGNOSIS AND TESTING) for engine oil pressure test/specifications 4. Clean/replace hydraulic tappets/ lash adjusters 5. Install new push rods 6. Inspect oil supply to rocker arms and replace worn arms as needed 7. Install new hydraulic tappets/lash adjusters 8. Inspect all valve guides and replace as necessary 9. Grind valves and seats
1. Check engine oil level. 2. Check engine oil level. If ok, Perform oil pressure test. (Refer to 9 - ENGINE/LUBRICATION - DIAGNOSIS AND TESTING) engine oil pressure test/specifications 3. Change oil to correct viscosity. (Refer to 9 - ENGINE/LUBRICATION/ OIL - STANDARD PROCEDURE) for correct procedure/engine oil specifications 4. Measure bearings for correct clearance with plasti-gage. Repair as necessary 5. Replace crankshaft or grind journals 6. Replace bent connecting rods
1. Check engine oil level. 2. Check engine oil level. If ok, Perform oil pressure test. (Refer to 9 - ENGINE/LUBRICATION - DIAGNOSIS AND TESTING) 3. Change oil to correct viscosity.
DR ENGINE - 5.9L (Continued)
ENGINE - 5.9L
9 - 229
CONDITION
POSSIBLE CAUSES
CORRECTION
LOW OIL PRESSURE
OIL LEAKS
4. Excessive main bearing clearance
5. Excessive end play
6. Crankshaft main journal out of round or worn 7. Loose flywheel or torque converter
1. Low oil level 2. Faulty oil pressure sending unit 3. Clogged oil filter 4. Worn oil pump 5. Thin or diluted oil 6. Excessive bearing clearance
7. Oil pump relief valve stuck
8. Oil pickup tube loose, broken, bent or clogged 9. Oil pump cover warped or cracked
1. Misaligned or deteriorated gaskets 2. Loose fastener, broken or porous metal part 3. Front or rear crankshaft oil seal leaking 4. Leaking oil gallery plug or cup plug
EXCESSIVE OIL CONSUMPTION OR SPARK PLUGS OIL FOULED
1. CCV System malfunction
2. Defective valve stem seal(s) 3. Worn or broken piston rings
4. Scuffed pistons/cylinder walls
5. Carbon in oil control ring groove 6. Worn valve guides
7. Piston rings fitted too tightly in grooves
4. Measure bearings for correct clearance. Repair as necessary 5. Check crankshaft thrust bearing for excessive wear on flanges 6. Grind journals or replace crankshaft
7. Inspect crankshaft, flexplate/ flywheel and bolts for damage. Tighten to correct torque
1. Check oil level and fill if necessary 2. Install new sending unit 3. Install new oil filter 4. Replace oil pump assembly. 5. Change oil to correct viscosity. 6. Measure bearings for correct clearance 7. Remove valve to inspect, clean and reinstall 8. Inspect oil pickup tube and pump, and clean or replace if necessary 9. Install new oil pump
1. Replace gasket 2. Tighten, repair or replace the part
3. Replace seal
4. Remove and reseal threaded plug. Replace cup style plug
1. (Refer to 25 - EMISSIONS CONTROL/EVAPORATIVE EMISSIONS - DESCRIPTION) for correct operation 2. Repair or replace seal(s) 3. Hone cylinder bores. Install new rings 4. Hone cylinder bores and replace pistons as required 5. Remove rings and de-carbon piston 6. Inspect/replace valve guides as necessary 7. Remove rings and check ring end gap and side clearance. Replace if necessary
ENGINE - 5.9L
9 - 230
ENGINE - 5.9L (Continued) DIAGNOSIS AND TESTING—ENGINE DIAGNOSIS - LUBRICATIONDR
CONDITION
OIL LEAKS
POSSIBLE CAUSES
CORRECTION
1. Gaskets and O-Rings.
1.
(a) Misaligned or damaged. (b) Loose fasteners, broken or porous metal parts. 2. Crankshaft rear seal 3. Crankshaft seal flange. Scratched, nicked or grooved. 4. Oil pan flange cracked. 5.Front cover seal, damaged or misaligned. 6. Scratched or damaged vibration damper hub.
(a) Replace as necessary. (b) Tighten fasteners, Repair or replace metal parts. 2. Replace as necessary. 3. Polish or replace crankshaft.
4. Replace oil pan. 5. Replace seal.
6. Polish or replace damper.
OIL PRESSURE DROP
1. Low oil level.
1. Check and correct oil level.
2. Faulty oil pressure sending unit. 3. Low oil pressure.
4. Clogged oil filter. 5. Worn oil pump. 6. Thin or diluted oil. 7. Excessive bearing clearance. 8. Oil pump relief valve stuck. 9. Oil pickup tube loose or damaged.
2. Replace sending unit. 3. Check pump and bearing clearance. 4. Replace oil filter. 5. Replace as necessary. 6. Change oil and filter. 7. Replace as necessary. 8. Replace oil pump. 9. Replace as necessary.
OIL PUMPING AT RINGS; SPARK
1. Worn or damaged rings.
PLUGS FOULING
2. Carbon in oil ring slots. 3. Incorrect ring size installed. 4. Worn valve guides. 5. Leaking intake gasket. 6. Leaking valve guide seals.
1. Hone cylinder bores and replace rings. 2. Replace rings. 3. Replace rings. 4. Ream guides and replace valves. 5. Replace intake gaskets. 6. Replace valve guide seals.
DR ENGINE - 5.9L (Continued) DIAGNOSIS AND TESTING—CYLINDER COMPRESSION PRESSURE
The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunc- tions.
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 (Refer to 8 - ELEC- TRICAL/IGNITION CONTROL/SPARK PLUG - REMOVAL).
(3) Secure the throttle in the wide-open position. (4) Disconnect the ignition coil. (5) Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions.
(6) Record the compression pressure on the third revolution. Continue the test for the remaining cylin- ders.
(Refer to 9 - ENGINE - SPECIFICATIONS) for the
correct engine compression pressures.
DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition. Combustion pressure leakage testing will detect: † Exhaust and intake valve leaks (improper seat- ing)† Leaks between adjacent cylinders or into water jacket
ENGINE - 5.9L
9 - 231
† Any causes for combustion/compression pressure
loss
WARNING: DO NOT REMOVE THE RADIATOR CAP WITH THE SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM HOT COOLANT CAN OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor- then turn OFF the
mal operating temperature, engine.
Remove the spark plugs. Remove the oil filler cap. Remove the air cleaner. Calibrate the tester according to the manufactur- er’s instructions. The shop air source for testing should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum and 552 kPa (80 psi) recom- mended.Perform the test procedure on each cylinder accord- ing to the tester manufacturer’s instructions. While testing, listen for pressurized air escaping through the throttle body, tailpipe or oil filler cap opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE: At 552 kPa (80 psi) input pres- sure, a minimum of 414 kPa (60 psi) should be main- tained in the cylinder CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART.
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
CONDITION
POSSIBLE CAUSE
CORRECTION
AIR ESCAPES THROUGH THROTTLE BODY AIR ESCAPES THROUGH TAILPIPE AIR ESCAPES THROUGH RADIATOR MORE THAN 50% LEAKAGE FROM ADJACENT CYLINDERS
MORE THAN 25% LEAKAGE AND AIR ESCAPES THROUGH OIL FILLER CAP OPENING ONLY
Intake valve bent, burnt, or not seated properly Exhaust valve bent, burnt, or not seated properly Head gasket leaking or cracked cylinder head or block Head gasket leaking or crack in cylinder head or block between adjacent cylinders Stuck or broken piston rings; cracked piston; worn rings and/or cylinder wall
Inspect valve and valve seat. Reface or replace, as necessary Inspect valve and valve seat. Reface or replace, as necessary Remove cylinder head and inspect. Replace defective part Remove cylinder head and inspect. Replace gasket, head, or block as necessary Inspect for broken rings or piston. Measure ring gap and cylinder diameter, taper and out-of-round. Replace defective part as necessary
ENGINE - 5.9L
9 - 232
ENGINE - 5.9L (Continued) STANDARD PROCEDURESTANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS
There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results. Do not use form-in- place gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket materials that are used in the engine area. Mopart Engine RTV GEN II, Mopart ATF-RTV, and Mopart Gasket Maker gasket materials, each have different properties and can not be used in place of the other.
MOPARt ENGINE RTV GEN II Mopart Engine RTV GEN II is used to seal com- ponents exposed to engine oil. This material is a spe- cially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.
MOPARt ATF RTV Mopart ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and seal- ing properties to seal components exposed to auto- matic coolants, and moisture. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.
transmission fluid,
engine
MOPARt GASKET MAKER Mopart Gasket Maker is an anaerobic type gasket material. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for use between two machined surfaces. Do not use on flexible metal flanges.
MOPARt GASKET SEALANT Mopart Gasket Sealant is a slow drying, perma- nently soft sealer. This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts under all temperatures. This mate- rial is used on engines with multi-layer steel (MLS) cylinder head gaskets. This material also will pre- vent corrosion. Mopart Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
DR
FORM-IN-PLACE GASKET AND SEALER APPLICATION
Assembling parts using a form-in-place gasket requires care but it’s easier than using precut gas- kets.
Mopart Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant to one gasket surface. Be certain the material sur- rounds each mounting hole. Excess material can eas- ily be wiped off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during assembly to prevent smear- ing material off the location.
Mopart Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 3 mm (0.120 in.) in diameter. All mounting holes must be circled. For corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towel. Components should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to prevent smearing material off the location.
Mopart Gasket Sealant in an aerosol can should be applied using a thin, even coat sprayed completely over both surfaces to be joined, and both sides of a gasket. Then proceed with assembly. Material in a can w/applicator can be brushed on evenly over the sealing surfaces. Material in an aerosol can should be used on engines with multi-layer steel gaskets.
STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain the original center line.
tially, this repair consists of:
Damaged or worn threads can be repaired. Essen- † Drilling out worn or damaged threads. † Tapping the hole with a special Heli-Coil Tap, or † Installing an insert into the tapped hole to bring
equivalent.
the hole back to its original thread size.
STANDARD PROCEDURE—HYDROSTATIC LOCK
CAUTION: DO NOT use the starter motor to rotate the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock (regardless of what caused the problem), follow the steps below.
ENGINE - 5.9L
9 - 233
strokes, depending on the bore condition, will be suf- ficient to provide a satisfactory surface. Using honing oil C-3501-3880, or a light honing oil, available from major oil distributors.
CAUTION: DO NOT use engine or transmission oil, mineral spirits, or kerosene.
(3) Honing should be done by moving the hone up and down fast enough to get a crosshatch pattern. The hone marks should INTERSECT at 40° to 60° for proper seating of rings (Fig. 3).
DR ENGINE - 5.9L (Continued)
(1) Perform the Fuel Pressure Release Procedure (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE).
(2) Disconnect the negative cable(s) from the bat-
tery.
(3) Inspect air
induction system, and intake manifold to ensure system is dry and clear of foreign material.
cleaner,
(4) Place a shop towel around the spark plugs to catch any fluid that may possibly be under pressure in the cylinder head. Remove the spark plugs.
(5) With all spark plugs removed, rotate the crank-
shaft using a breaker bar and socket.
(6) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
cylinders.
(7) Be sure all fluid has been removed from the
(8) Repair engine or components as necessary to
prevent this problem from occurring again.
(9) Squirt a small amount of engine oil into the cylinders to lubricate the walls. This will prevent damage on restart.
(10) Install new spark plugs. Tighten the spark
plugs to 41 N·m (30 ft. lbs.) torque.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N·m (25 ft. lbs.) torque.
(13) Install a new oil filter. (14) Fill engine crankcase with the specified amount and grade of oil. (Refer to LUBRICATION & MAINTENANCE - SPECIFICATIONS).
(15) Connect the negative cable(s) to the battery. (16) Start the engine and check for any leaks.
STANDARD PROCEDURE - CYLINDER BORE HONING
Before honing, stuff plenty of clean shop towels under the bores and over the crankshaft to keep abrasive materials from entering the crankshaft area.
(1) Used carefully, the Cylinder Bore Sizing Hone C-823, equipped with 220 grit stones, is the best tool for this job. In addition to deglazing, it will reduce taper and out-of-round, as well as removing light scuffing, scoring and scratches. Usually, a few strokes will clean up a bore and maintain the required lim- its.
CAUTION: DO NOT use rigid type hones to remove cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done if the cylinder bore is straight and round. Use a cylin- der surfacing hone, Honing Tool C-3501, equipped with 280 grit stones (C-3501-3810). about 20-60
Fig.3CylinderBoreCrosshatchPattern
1 - CROSSHATCH PATTERN 2 - INTERSECT ANGLE
(4) A controlled hone motor speed between 200 and 300 RPM is necessary to obtain the proper cross- hatch angle. The number of up and down strokes per minute can be regulated to get the desired 40° to 60° angle. Faster up and down strokes increase the cross- hatch angle.
(5) After honing, it is necessary that the block be cleaned to remove all traces of abrasive. Use a brush to wash parts with a solution of hot water and deter- gent. Dry parts thoroughly. Use a clean, white, lint- free cloth to check that the bore is clean. Oil the bores after cleaning to prevent rusting.
REMOVAL
(1) Disconnect the battery negative cable. (2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
ENGINE - 5.9L
9 - 234
ENGINE - 5.9L (Continued)DR
from a/c
refrigerant
(3) Recover
if equipped (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING - STANDARD PROCEDURE). (4) Remove the a/c condenser, if equipped (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/ A/C CONDENSER - REMOVAL).
system,
(5) Remove the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS REMOVAL).
COOLER
(6) Remove the washer bottle from the fan shroud. (7) Remove the viscous fan/drive (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL). (8) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(9) Remove the upper crossmember and top core
support.
(10) Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(11) Remove the A/C compressor with the lines
attached. Secure compressor out of the way.
(12) Remove generator assembly (Refer to 8 - ELECTRICAL/CHARGING/GENERATOR - REMOV- AL).
(13) Remove the air cleaner resonator and duct
work as an assembly.
(14) Disconnect the throttle linkage (Refer to 14 - INJECTION/THROTTLE
SYSTEM/FUEL
FUEL CONTROL CABLE - REMOVAL).
(15) Remove throttle body (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/THROTTLE BODY - REMOVAL).
(16) Remove the intake manifold (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE REMOVAL).
(17) Remove the distributor cap and wiring. (18) Disconnect the heater hoses. (19) Disconnect
the power
steering hoses,
if
equipped.
(20) Perform the Fuel System Pressure Release procedure (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE).
(21) Disconnect the fuel supply line (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CON- NECT FITTING - STANDARD PROCEDURE).
(22) On Manual Transmission vehicles, remove the shift lever (Refer to 21 - TRANSMISSION/TRANS- AXLE/MANUAL/SHIFT COVER - REMOVAL).
(23) Raise and support the vehicle on a hoist and
drain the engine oil.
(24) Remove engine front mount thru-bolt nuts. (25) Disconnect the transmission oil cooler lines
from their retainers at the oil pan bolts.
(26) Disconnect exhaust pipe at manifolds.
(27) Disconnect the starter wires. Remove starter to 8 - ELECTRICAL/STARTING/
motor STARTER MOTOR - REMOVAL).
(Refer
(28) Remove the dust shield and transmission
inspection cover.
(29) Remove drive plate to converter bolts (Auto-
matic transmission equipped vehicles).
(30) Remove transmission bell housing to engine
block bolts.
(31) Lower the vehicle. (32) Install an engine lifting fixture. (33) Separate engine from transmission, remove engine from vehicle, and install engine assembly on a repair stand.
INSTALLATION
(1) Remove engine from the repair stand and posi- tion in the engine compartment. Position the thru- bolt into the support cushion brackets.
engine with transmission:
(2) Install engine lifting device. (3) Lower engine into compartment and align † Manual Transmission: Align clutch disc assem- bly (if disturbed). Install transmission input shaft into clutch disc while mating engine and transmis- sion surfaces. Install two transmission to engine block mounting bolts finger tight. † Automatic Transmission: Mate engine and trans- mission and install two transmission to engine block mounting bolts finger tight.
(4) Lower engine assembly until engine mount
through bolts rest in mount perches.
(5) Install remaining transmission to engine block
mounting bolts and tighten.
(6) Tighten engine mount through bolts. (7) Install drive plate to torque converter bolts.
(Automatic transmission models)
the starter and connect
(8) Install the dust shield and transmission cover. (9) Install the starter to 8 - ELECTRICAL/STARTING/ (Refer
wires STARTER MOTOR - INSTALLATION). (10) Install exhaust pipe to manifold. (11) Install the transmission cooler line brackets to
the oil pan.
(25 ft. lbs.) torque.
(12) Install the drain plug and tighten to 34 N·m
(13) Lower the vehicle. (14) Remove engine lifting fixture. (15) On Manual Transmission vehicles, install the shift lever (Refer to 21 - TRANSMISSION/TRANS- AXLE/MANUAL/SHIFT COVER - INSTALLATION). (16) Connect the fuel supply line (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CON- NECT FITTING - STANDARD PROCEDURE).
(17) Connect the power steering hoses, if equipped. (18) Connect the heater hoses.
DR ENGINE - 5.9L (Continued)
ENGINE - 5.9L
9 - 235
(19) Install the distributor cap and wiring. (20) Install
the intake manifold (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE INSTALLATION).
(21) Using a new gasket,
throttle body (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/ THROTTLE BODY - INSTALLATION).
install
(22) Connect the throttle linkage (Refer to 14 - INJECTION/THROTTLE
FUEL CONTROL CABLE - INSTALLATION).
SYSTEM/FUEL
(23) Install the air cleaner resonator and duct
work..
(24) Install the generator and wire connections (Refer to 8 - ELECTRICAL/CHARGING/GENERA- TOR - INSTALLATION).
(25) Install a/c compressor and lines (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C COMPRESSOR - INSTALLATION).
(26) Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(27) Install upper radiator support crossmember. (28) Install radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - INSTALLATION).
(29) Connect the radiator lower hose. (30) Connect the transmission oil cooler lines to
the radiator.
(31) Install the fan shroud. (32) Install the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
(33) Connect the radiator upper hose. (34) Install the washer bottle. (35) Install the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS INSTALLATION).
COOLER
(36) Connect the transmission cooler lines. (37) If equipped, install the condenser (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/ A/C CONDENSER - INSTALLATION).(38) Evacuate and charge the air conditioning sys- tem, if equipped (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO- CEDURE).
(39) Add engine oil to crankcase (Refer to LUBRI- CATION & MAINTENANCE/FLUID TYPES - SPEC- IFICATIONS).
(40) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(41) Connect battery negative cable. (42) Start engine and inspect for leaks. (43) Road test vehicle.
SPECIFICATIONS
5.9L ENGINE
ENGINE SPECIFICATIONS
DESCRIPTION
SPECIFICATION
GENERAL SPECIFICATIONS
Engine Type
90° V-8 OHV
Bore and Stroke
101.6 x 90.9 mm (4.00 x 3.58 in.)
Displacement
5.9L (360 c.i.)
Compression Ratio
9.1:1
Firing Order
Lubrication
1–8–4–3–6–5–7–2
Pressure Feed – Full
Flow
Filtration
Cooling System
Liquid Cooled – Forced
Cylinder Block
Cylinder Head
Crankshaft
Camshaft
Pistons
Circulation
Cast Iron
Cast Iron
Nodular Iron
Nodular Cast Iron
Aluminum Alloy w/strut
Connecting Rods
Forged Steel
Compression Pressure
689.5 kPa (100 psi)
(Min.)
CAMSHAFT
Bearing Diameter
No. 1
No. 2
No. 3
No. 4
No. 5
50.800 – 50.825 mm (2.000 – 2.001 in.) 50.394 – 50.419 mm (1.984 – 1.985 in.) 50.013 – 50.038 mm (1.969 – 1.970 in.) 49.606 – 49.632 mm (1.953 – 1.954 in.) 39.688 – 39.713 mm (1.5625 – 1.5635 in.)
ENGINE - 5.9L
9 - 236
ENGINE - 5.9L (Continued)DR
DESCRIPTION
SPECIFICATION
DESCRIPTION
SPECIFICATION
Bearing Journal Diameter No. 1
No. 2
No. 3
No. 4
No. 5
Bearing to Journal
Clearance
Standard
Service Limit
Camshaft End Play
50.723 – 50.775 mm (1.997 – 1.999 in.) 50.317 – 50.368 mm (1.981 – 1.983 in.) 49.936 – 49.987 mm (1.966 – 1.968 in.) 49.53 – 49.581 mm (1.950 – 1.952 in.) 39.611 – 39.662 mm (1.5595 – 1.5615 in.)
0.0254 – 0.0762 mm (0.001 – 0.003 in.) 0.127 mm (0.005 in.)
0.051 – 0.254 mm (0.002 – 0.010 in.)
CONNECTING RODS
Piston Pin bore Diameter
Side Clearance
24.966 – 24.978 mm (0.9829 – 0.9834 in.)
0.152 – 0.356 mm (0.006 – 0.014 in.)
CRANKSHAFT
Rod Journal
Diameter
Out of Round (Max.) Taper (Max.) Bearing Clearance
53.950 – 53.975 mm (2.124 – 2.125 in.)
0.0254 mm (0.001 in.) 0.0254 mm (0.001 in.)
0.013 – 0.056 mm
(0.0005 – 0.0022 in.)
Main Bearing Journal
Diameter
71.361 – 71.387 mm (2.8095 – 2.8105 in.)
Out of Round (Max.)
0.127 mm (0.001 in.)
Journals # 2 - 5
Service Limit
(0.0005 – 0.0015 in.)
0.013 – 0.051 mm (0.0005 – 0.002 in.)
Journal #1
Journals #2-50.0381 mm (0.0015 in.) 0.064 mm (0.0025 in.)
Crankshaft End Play
Service Limit
0.051 – 0.178 mm (0.002 – 0.007 in.) 0.254 mm (0.010 in.)
CYLINDER BLOCK
Cylinder Bore
Diameter
101.60 – 101.65 mm (4.000 – 4.002 in.)
Out of Round (Max.) Taper (Max.)
0.0254 mm (0.001 in.) 0.0254 mm (0.001 in.)
Lifter Bore
Diameter
22.99 – 23.01 mm
(0.9051 – 0.9059 in.)
Distributor Drive Bushing Press Fit
Bushing to Bore Interference
Shaft to Bushing Clearance
0.0127 – 0.3556 mm
(0.0005 – 0.0140 in.) 0.0178 – 0.0686 mm
(0.0007 – 0.0027 in.)
CYLINDER HEAD AND VALVES
Valve Seat
Angle
44.25° – 44.75°
Runout (Max.)
0.0762 mm (0.003 in.)
Width (Finish)
Intake
Exhaust
1.016 – 1.524 mm (0.040 – 0.060 in.) 1.524 – 2.032 mm (0.060 – 0.080 in.)
43.25° – 43.75°
Taper (Max.)
0.0254 mm (0.001 in.)
Valves
Bearing Clearance
Journal #1
0.013 – 0.038 mm
Face Angle
Head Diameter
DR ENGINE - 5.9L (Continued)
ENGINE - 5.9L
9 - 237
DESCRIPTION
SPECIFICATION
