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DESCRIPTION
SPECIFICATION
Intake Exhaust
47.752 mm (1.88 in.)
41.072 (1.617 in.)
Length (Overall)
Intake
Exhaust
126.21 – 126.85 mm (4.969 – 4.994 in.) 126.44 – 127.30 mm (4.978 – 5.012 in.)
Lift (@ zero lash)
Intake Exhaust
10.414 mm (0.410 in.) 10.592 mm (0.417 in.)
Stem Diameter
Intake
Exhaust
Guide Bore
Stem to Guide Clearance Intake
Exhaust
Service Limit
Valve Springs
9.449 - 9.474 mm (0.372 - 0.373 in.) 9.423 - 9.449 mm (0.371 - 0.372 in.)
9.500 - 9.525 mm (0.374 - 0.375 on.)
0.0254 - 0.0762 mm (0.001 - 0.003 in.) 0.0508 - 0.1016 mm (0.002 - 0.004 in.)
0.4318 - (0.017 in.)
Free Length
49.962 mm (1.967 in.)
Spring Tension
Valve closed
Valve open
378 N @ 41.66 mm (85 lbs. @ 1.64 in.) 890 N @ 30.89 mm (200 lbs. @ 1.212 in.)
Number of Coils
6.8
Installed Height
41.66 mm (1.64 in.)
Wire Diameter
4.50 mm (0.177 in.)
Dry Lash
Push Rod Length
(0.0011 - 0.0024 in.)
1.524 - 5.334 mm (0.060 - 0.210 in.)
175.64 - 176.15 mm (6.915 - 6.935 in.)
OIL PRESSURE
Curb Idle (Min.*)
41.4 kPa (6 psi)
@ 3000 rpm
207 - 552 kPa (30 - 80
psi)
Oil Pressure Bypass
Valve Setting
62 - 103 kPa (9 - 15 psi)
Switch Actuating
Pressure
34.5 - 48.3 kPa (5 - 7
psi)
* If oil pressure is zero at curb idle, DO NOT RUN ENGINE.
OIL PUMP
Clearance over Rotors
0.1016 mm (0.004 in.)
(Max.)
Cover Out of Flat (Max.)
0.0381 mm (0.0015 in.)
Inner Rotor Thickness
20.955 mm (0.825 in.)
(Min.)
Outer Rotor
Clearance (Max.) Diameter (Min.) Thickness (Min.)
0.3556 mm (0.014 in.) 62.7126 mm (2.469 in.) 20.955 mm (0.825 in.)
Tip Clearance between
Rotors (Max.)
0.2032 mm (0.008 in.)
PISTONS
Clearance at Top of Skirt
0.013 - 0.038 mm
Land Clearance (Diam.)
(0.0005 - 0.0015 in.)
0.508 - 0.660 mm (0.020 - 0.026 in.)
HYDRAULIC TAPPETS
Piston Length
81.03 mm (3.19 in.)
Body Diameter
22.949 - 22.962 mm (0.9035 - 0.9040 in.)
Clearance (to bore)
0.0279 - 0.0610 mm
Piston Ring Groove
Depth Groove #1 and 2
4.761 - 4.912 mm
ENGINE - 5.9L
9 - 238
ENGINE - 5.9L (Continued)DR
DESCRIPTION
SPECIFICATION
DESCRIPTION
SPECIFICATION
Groove #3
Weight
(0.187 - 0.193 in.) 3.996 - 4.177 mm (0.157 - 0.164 in.) 582 - 586 grams (20.53 - 20.67 oz.)
Intake Valve
Closes (ATDC) Opens (BBDC) Duration
Valve Overlap
62° 7° 249°
41°
PISTON PINS
Clearance in Piston
0.006 - 0.019 mm
OVERSIZE AND UNDERSIZE ENGINE
COMPONENT MARKINGS CHART
OS-US
Item
Identification
Location of Identification
U/S
Crankshaft
R or M M-2-3
Milled flat on
(0.00023 - 0.00074 in.)
25.007 - 25.015 mm (0.9845 - 0.9848 in.)
NONE
67.8 - 68.3 mm (2.67 - 2.69 in.)
PISTON RINGS
Diameter
End Play
Length
Ring Gap
Compression Ring (Top)
0.30 - 0.55 mm
(0.012 - 0.022 in.)
Compression Ring (2nd)
0.55 - 0.80 mm
Oil Control (Steel Rails)
Ring Side Clearance
(0.022 - 0.031 in.)
0.381 - 1.397 mm (0.015 - 0.055 in.)
Compression Rings
0.040 - 0.085 mm
.025 MM
(.001 in.)
O/S
.508 mm (.020 in.)
Cylinder Bores
(0.0016 - 0.0033 in.)
O/S
Tappets
Oil Ring (Steel Rails)
0.05 - 0.21 mm
MAX
(0.002 - 0.008 in.)
.203 mm (.008 in.)
ect.
(indicating No.
No. three
2 and
3 main bearing journal) and/or
R-1-4 ect.
(indicating No.
1 and
4 connecting
rod
journal)
crankshaft counter- weight.
Following
engine serial
number.
3/89
diamond -shaped stamp Top
pad
— Front of engine and
flat
ground on
outside surface
of each O/S tappet bore.
Ring Width Compression rings
Oil Ring (Steel Rails) Max.
1.530 - 1.555 mm (0.060 - 0.061 in.) 0.447 - 0.473 mm
(0.018 - 0.019 in.)
VALVE TIMING
Exhaust Valve
Closes (ATDC) Opens (BBDC) Duration
33° 56° 269°
O/S
Valve Stems
Milled pad
DR ENGINE - 5.9L (Continued)
ENGINE - 5.9L
9 - 239
DESCRIPTION
N·m
Ft. Lbs. 50
In. Lbs. —
Rear Insulator to Bracket Through-Bolt (2WD) Rear Insulator to Crossmember Support Bracket Nut (2WD) Rear Insulator to Crossmember Nuts (4WD) Rear Insulator to Transmission Bolts (4WD) Rear Insulator Bracket Bolts (4WD Automatic) Rear Support Bracket to Crossmember Flange Nuts Rear Support Plate to Transfer Case Bolts Rocker Arm Bolts Spark Plugs Starter Motor Mounting Bolts Thermostat Housing Bolts Throttle Body Bolts Torque Converter Drive Plate Bolts Transfer Case to Insulator Mounting Plate Nuts Transmission Support Bracket Bolts (2WD) Vibration Damper Bolt Water Pump to Timing Chain Case Cover Bolts
68
41
68
68
68
41
41
28
41
68
25
23
3130
50
50
50
30
30
21
30
50
— — —204
105
68
50
244
41180
30—
—
—
—
—
—
— — — 225
200
270—
—
— —
Item
Identification
Location of adjacent to
two
3/89 tapped
holes on
each end of cylinder head.
OS-US .127 mm
(.005 in.)
TORQUE
TORQUE CHART 5.9L ENGINE
DESCRIPTION
N·m
Camshaft Sprocket Bolt Camshaft Thrust Plate Bolts Timing Chain Case Cover Bolts Connecting Rod Cap Bolts Main Bearing Cap Bolts Crankshaft Pulley Bolts Cylinder Head Bolts
Step 1
Step 2Cylinder Head Cover Bolts Engine Support Bracket to Block Bolts (4WD) Exhaust Manifold to Cylinder Head Bolts/Nuts Flywheel Bolts Front Insulator Through bolt/nut Front Insulator to Support Bracket
Stud Nut (4WD) Through Bolt/Nut (4WD)
Front Insulator to Block Bolts (2WD) Generator Mounting Bolt Intake Manifold Bolts Oil Pan Bolts Oil Pan Drain Plug Oil Pump Attaching Bolts Oil Pump Cover Bolts
Ft. Lbs. 50
— 3045
85
—50
105
— 3025
55
7030
75
70In. Lbs. — 210
—— — 210
— — 95
——
— —
— — —
68
24
4161
115
2468
143
11
4134
75
9541
102
9530
41
— Refer to Procedure 24
215
— 34
— 41
11
95— 25
30
—ENGINE - 5.9L
9 - 240
ENGINE - 5.9L (Continued) SPECIAL TOOLS5.9L ENGINE
DR
OilPressureGaugeC-3292
EngineSupportFixtureC-3487–A
ValveSpringCompressorMD-998772–A
Adaptor6633
Adaptor6716A
ValveGuideSleeveC-3973
DialIndicatorC-3339
PullerC-3688
Puller1026
CrankshaftDamperRemovalInsert8513
DR ENGINE - 5.9L (Continued)
ENGINE - 5.9L
9 - 241
FrontOilSealInstaller6635
CrankshaftMainBearingRemoverC-3059
CamBearingRemover/InstallerC3132–A
CylinderBoreGaugeC-119
CamshaftHolderC-3509
PressureTesterKit7700
DistributorBushingPullerC-3052
Bloc–Check–KitC-3685–A
DistributorBushingDriver/BurnisherC-3053
ENGINESUPPORTFIXTURE8534
PistonRingCompressorC-385
9 - 242
ENGINE - 5.9L
DR
AIR CLEANER ELEMENT REMOVAL
Filter Element Only
(2) Lift entire housing assembly from 4 locating
pins (Fig. 5).
Housing removal is not necessary for element (fil-
ter) replacement.
at air cleaner cover.
(1) Loosen clamp (Fig. 4) and disconnect air duct
(2) Pry over 4 spring clips (Fig. 4) from housing
cover (spring clips retain cover to housing).
(3) Release housing cover from locating tabs on
housing (Fig. 4) and remove cover.
(4) Remove air cleaner element (filter) from hous-
(5) Clean inside of housing before replacing ele-
ing.
ment.
Fig.5AIRCLEANERHOUSING
1 - AIR CLEANER HOUSING ASSEMBLY 2 - LOCATING PINS (4)
INSTALLATION
(1) Install filter element into housing. (2) Position housing cover into housing locating
(3) Pry up 4 spring clips (Fig. 4) and lock cover to
tabs (Fig. 4).
housing.
(4) Install air duct to air cleaner cover and tighten
hose clamp to 3 N·m (30 in. lbs.) torque.
(5) If any other hose clamps were removed from air intake system, tighten them to 3.4 N·m (30 in. lbs.) torque.
(6) If any bolts were removed from air resonator housing or air intake tubing, tighten them to 4.5 N·m (40 in. lbs.) torque.
Fig.4AIRCLEANERHOUSINGCOVER
1 - CLAMP 2 - AIR DUCT 3 - AIR CLEANER COVER 4 - LOCATING TABS 5 - CLIPS (4)
Housing Assembly
(1) Loosen clamp (Fig. 4) and disconnect air duct
at air cleaner cover.
DR
ENGINE - 5.9L
9 - 243
CYLINDER HEAD
OPERATION
DESCRIPTION
DESCRIPTION—CYLINDER HEAD
The cast iron cylinder heads (Fig. 6) are mounted to the cylinder block using ten bolts. The spark plugs are located in the peak of the wedge between the valves.
OPERATION—CYLINDER HEAD
The cylinder head closes the combustion chamber allowing the pistons to compress the air fuel mixture to the correct ratio for ignition. The valves located in the cylinder head open and close to either allow clean air into the combustion chamber or to allow the exhaust gases out, depending on the stroke of the engine.
OPERATION - CYLINDER HEAD COVER GASKET
The steel-backed silicone gasket is designed to seal the cylinder head cover for long periods of time through extensive heat and cold, without failure. The gasket is designed to be reusable.
DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET FAILURE
Fig.6CylinderHeadAssembly—V-8GasEngines 1 - EXHAUST VALVE 2 - SPARK PLUGS 3 - EXHAUST VALVES 4 - SPARK PLUGS 5 - EXHAUST VALVE 6 - INTAKE VALVES 7 - INTAKE VALVES
DESCRIPTION - CYLINDER HEAD COVER GASKET
The cylinder head cover gasket (Fig. 7) is a steel- backed silicone gasket, designed for long life usage.
Fig.7CylinderHeadCoverGasketV-8GasEngines 1 - CYLINDER HEAD COVER GASKET
A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket. † Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
− Loss of engine power − Engine misfiring − Poor fuel economy
† Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are:
− Engine overheating − Loss of coolant − Excessive steam (white smoke) emitting from
exhaust
− Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the proce- dures in Cylinder Compression Pressure Test in this section. An engine cylinder head gasket leaking between adjacent cylinders will result in approxi- mately a 50–70% reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRES- SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure cap. Start the engine and allow it to warm up until thermostat opens.
ENGINE - 5.9L
9 - 244
CYLINDER HEAD (Continued)If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST. EXCES- SIVE PRESSURE BUILT UP, BY CONTINUOUS ENGINE OPERATION, MUST BE RELEASED TO A SAFE PRESSURE POINT. NEVER PERMIT PRES- SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to pressure cap neck. Start the engine and observe the tester’s pressure gauge. If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also be checked by using Bloc-Chek Kit C-3685-A or equivalent. Perform test following the procedures supplied with the tool kit.
REMOVAL
(1) Disconnect the battery negative cable. (2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the air cleaner resonator and duct
work.
(4) Remove
the
intake manifold-to-generator
bracket support rod. Remove the generator.
(5) Remove closed crankcase ventilation system. (6) Disconnect the evaporation control system. (7) Perform the Fuel System Pressure Release pro- cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV- ERY - STANDARD PROCEDURE). Disconnect the fuel supply line (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STAN- DARD PROCEDURE).
(8) Disconnect accelerator
so equipped, the speed control and transmission kick- down cables.
linkage and if
(9) Remove distributor cap and wires. (10) Disconnect the coil wires. (11) Disconnect heat indicator sending unit wire. (12) Disconnect heater hoses and bypass hose. (13) Remove the master
cylinder and booster
assembly. Refer to section 5 brakes.
(14) Remove cylinder head covers and gaskets (Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN- DER HEAD COVER(S) - REMOVAL).
(15) Remove
intake manifold (Refer
to 9 - ENGINE/MANIFOLDS/INTAKE REMOVAL) and throttle body as an assembly. Dis- card the flange side gaskets and the front and rear cross-over gaskets.
MANIFOLD
DR
(16) Remove exhaust manifolds (Refer
to 9 - ENGINE/MANIFOLDS/EXHAUST MANIFOLD - REMOVAL).
(17) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations.
(18) Remove the head bolts from each cylinder head and remove cylinder heads. Discard the cylin- der head gasket.
(19) Remove spark plugs.
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
INSPECTION
Inspect all surfaces with a straightedge if there is any reason to suspect If out-of-flatness exceeds 0.00075mm/mm (0.0001in/in.) times the span length in any direction, either replace head or lightly machine the head surface.
leakage.
FOR EXAMPLE:—A 305 mm (12 in.) span is 0.102 mm (0.004 in.) out-of-flat. The allowable out-of- flat is 305 x 0.00075 (12 x 0.00075) equals 0.23 mm (0.009 in.). This amount of out-of-flat is acceptable.
The
cylinder head surface
finish should be
1.78-3.00 microns (70-125 microinches).
Inspect push rods. Replace worn or bent rods.
INSTALLATION
(1) Clean all surfaces of cylinder block and cylin-
der heads.
(2) Clean cylinder block front and rear gasket sur-
faces using a suitable solvent.
(3) Position new cylinder head gaskets onto the
cylinder block.
cylinder block.
(4) Position cylinder heads onto head gaskets and
(5) Starting at top center, tighten all cylinder head
bolts, in sequence (Fig. 8).
CAUTION: When tightening the rocker arm bolts, make sure the piston in that cylinder is NOT at TDC. Contact between the valves and piston could occur.
(6) Install push rods and rocker arm assemblies in their original position. Tighten the bolts to 28 N·m (21 ft. lbs.) torque.
(7) Install
the intake manifold (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE INSTALLATION) and throttle body assembly.
(8) Install
exhaust manifolds
to 9 - ENGINE/MANIFOLDS/EXHAUST MANIFOLD - INSTALLATION).
(Refer
DR CYLINDER HEAD (Continued)
ENGINE - 5.9L
9 - 245
CYLINDER HEAD COVER(S) REMOVAL
NOTE: A steel backed silicon gasket is used with the cylinder head cover (Fig. 9). This gasket can be used again.
Fig.8CylinderHeadBoltTighteningSequence (9) If required, adjust spark plugs to specifications. Install the plugs and tighten to 41 N·m (30 ft. lbs.) torque.
(10) Install coil wire. (11) Connect heat indicator sending unit wire. (12) Connect the heater hoses and bypass hose. (13) Install distributor cap and wires. (14) Connect
the accelerator linkage and if so equipped, the speed control and transmission kick- down cables.
(15) Install the fuel supply line (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CON- NECT FITTING - STANDARD PROCEDURE).
(16) Install the generator and drive belt (Refer to 7
- COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION). Tighten generator mounting bolt to 41 N·m (30 ft. lbs.) torque. Tighten the adjusting strap bolt to 23 N·m (200 in. lbs.) torque.(17) Install
the
intake manifold-to-generator
bracket support rod. Tighten the bolts.
(18) Place the cylinder head cover gaskets in posi- tion and install cylinder head covers (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
(19) Install closed crankcase ventilation system. (20) Connect the evaporation control system. (21) Reinstall
the master cylinder and booster
assembly. Refer to section 5 brakes.
(22) Install the air cleaner. (23) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(24) Connect the negative cable to the battery. (25) Start engine check for leaks.
Fig.9CylinderHeadCoverGasket
1 - CYLINDER HEAD COVER GASKET
(1) Disconnect the negative cable from the battery. (2) Disconnect the spark plug wires form the spark
plugs and set aside.
(3) Disconnect closed ventilation system and evap-
oration control system from cylinder head cover.
(4) Remove cylinder head cover and gasket.
CLEANING
Clean cylinder head cover gasket surface. Clean head rail, if necessary.
INSPECTION
Inspect cover for distortion and straighten, if nec-
essary.
Check the gasket for use in head cover installation.
If damaged, use a new gasket.
INSTALLATION
(1) The cylinder head cover gasket can be used
again. Install the gasket onto the head rail.
(2) Position the cylinder head cover onto the gas- ket. Tighten the bolts to 11 N·m (95 in. lbs.) torque. (3) Install closed crankcase ventilation system and
evaporation control system.
(4) Connect the spark plug wires to the spark
plugs.
(5) Connect the negative cable to the battery.
9 - 246
ENGINE - 5.9L
DR
(2) Attach dial indicator Tool C-3339 to cylinder head and set it at right angles to valve stem being measured (Fig. 11).
INTAKE/EXHAUST VALVES & SEATS DESCRIPTION
Both the intake and exhaust valves are made of steel. The intake valve is 48.768 mm (1.92 inches) in diameter and the exhaust valve is 41.148 mm (1.62
inches) in diameter and has a 2.032 mm (0.080 inch) wafer interia welded to the tip for durability. These valves are not splayed.STANDARD PROCEDURE—VALVES, GUIDES AND SPRINGS
VALVE CLEANING
Clean valves thoroughly. Discard burned, warped,
or cracked valves.
Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner.
VALVE GUIDES
Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 in.), replace the valve.
Measure valve stem guide clearance as follows: (1) Install Valve Guide Sleeve Tool C-3973 over valve stem and install valve (Fig. 10). The special sleeve places the valve at the correct height for checking with a dial indicator.
Fig.11MeasuringValveGuideWear
1 - VALVE 2 - SPECIAL TOOL C-3339
(3) Move valve to and from the indicator. The total dial indicator reading should not exceed 0.432 mm (0.017 in.). Ream the guides for valves with oversize stems if dial indicator reading is excessive or if the stems are scuffed or scored.
VALVE GUIDES
Service valves with oversize stems are available.
Refer to REAMER SIZES CHART
REAMER SIZES CHART
Fig.10PositioningValvewithToolC-3973
1 - VALVE 2 - SPACER TOOL
REAMER O/S
VALVE GUIDE SIZE
0.076 mm (0.003 in.) 0.381 mm (0.015 in.)
8.026 - 8.052 mm (0.316 - 0.317 in.) 8.331 - 8.357 mm (0.328 - 0.329 in.)
(1) Slowly turn reamer by hand and clean guide thoroughly before installing new valve. Ream the valve guides from standard to 0.381 mm (0.015
in.). Use a two step procedure so the valve guides are reamed true in relation to the valve seat:† Step 1—Ream to 0.0763 mm (0.003 inch). † Step 2—Ream to 0.381 mm (0.015 inch).DR INTAKE/EXHAUST VALVES & SEATS (Continued) REFACING VALVES AND VALVE SEATS
VALVES
ENGINE - 5.9L
9 - 247
The intake and exhaust valves have a 43-1/4° to 43-3/4° face angle and a 44-1/4° to 44-3/4° seat angle (Fig. 12).
Inspect the remaining margin after the valves are refaced (Fig. 13). Valves with less than 1.190 mm (0.047 in.) margin should be discarded.
Fig.12ValveFaceandSeatAngles
1 - CONTACT POINT A,B,C and D
Fig.13IntakeandExhaustValves
1 - MARGIN 2 - VALVE SPRING RETAINER LOCK GROOVE 3 - STEM 4 - FACE
VALVE FACE AND VALVE SEAT ANGLE CHART
VALVE SEATS
ITEM
DESCRIPTION
SPECIFICATION
SEAT WIDTH
INTAKE
EXHAUST
1.016 - 1.524 mm (0.040 - 0.060 in.) 1.524 - 2.032 mm (0.060 - 0.080 in.)
FACE ANGLE (INT. AND EXT.)
SEAT ANGLE (INT. AND EXT.)
CONTACT SURFACE
431⁄4° - 433⁄4°
441⁄4° - 443⁄4°
—
CAUTION: DO NOT un-shroud valves during valve seat refacing (Fig. 14).
Fig.14RefacingValveSeats
1 - STONE 2 - PILOT 3 - VALVE SEAT 4 - SHROUD
(1) When refacing valve seats, it is important that the correct size valve guide pilot be used for reseat-
ENGINE - 5.9L
9 - 248
INTAKE/EXHAUST VALVES & SEATS (Continued)ing stones. A true and complete surface must be obtained.
(2) Measure the concentricity of valve seat using a dial indicator. Total runout should not exceed 0.051
mm (0.002 in.) total indicator reading.(3) Inspect the valve seat with Prussian blue, to determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian blue then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of valve face, contact is satisfactory. If the blue is trans- ferred to the top edge of valve face, lower valve seat with a 15° stone. If the blue is transferred to bottom edge of valve face raise valve seat with a 60° stone. (4) When seat is properly positioned the width of intake seats should be 1.016-1.524 mm (0.040-0.060
in.). The width of the exhaust seats should be 1.524- 2.032 mm (0.060-0.080 in.).VALVE SPRINGS
Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested. As an example the compression length of the spring to be tested is 1-5/16 in.. Turn table of Universal Valve Spring Tester Tool until surface is in line with the 1-5/16 in. mark on the threaded stud. Be sure the zero mark is to the front (Fig. 15). Place spring over stud on the table and lift compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by 2. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Refer to specifications to obtain specified height and allowable tensions. Discard the springs that do not meet specifications.
Fig.15TestingValveSpringforCompressed
Length
1 - TORQUE WRENCH 2 - VALVE SPRING TESTER
DR
to 9 -
REMOVAL
(1) Remove the cylinder head (Refer ENGINE/CYLINDER HEAD - REMOVAL).
(2) Compress valve springs using Valve Spring
Compressor Tool MD- 998772A and adapter 6716A.
(3) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(4) Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to ensure installation in original location.
CLEANING
or cracked valves.
Clean valves thoroughly. Discard burned, warped,
Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner.
INSPECTION
Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 in.), replace the valve.
Measure valve stem guide clearance as follows: (1) Install Valve Guide Sleeve Tool C-3973 over valve stem and install valve (Fig. 16). The special sleeve places the valve at the correct height for checking with a dial indicator.
Fig.16PositioningValvewithToolC-3973
1 - VALVE 2 - SPACER TOOL
(2) Attach dial indicator Tool C-3339 to cylinder head and set it at right angles to valve stem being measured (Fig. 17).
(3) Move valve to and from the indicator. The total dial indicator reading should not exceed 0.432 mm (0.017 in.). Ream the guides for valves with oversize stems if dial indicator reading is excessive or if the stems are scuffed or scored.
INSTALLATION
(1) Clean valves
thoroughly. Discard burned,
warped and cracked valves.
(2) Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner.
DR INTAKE/EXHAUST VALVES & SEATS (Continued)
ENGINE - 5.9L
9 - 249
(3) Remove the push rods and place them on a
bench in the same order as removed.
Fig.17MeasuringValveGuideWear
1 - VALVE 2 - SPECIAL TOOL C-3339
(3) Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 inch), replace the valve.
(4) Coat valve stems with lubrication oil and insert
them in cylinder head.
(5) If valves or seats are reground, check valve stem height. If valve is too long, replace cylinder head.
(6) Install new seals on all valve guides. Install
valve springs and valve retainers.
(7) Compress valve springs with Valve Spring Compressor Tool MD-998772A and adapter 6716A, install locks and release tool. If valves and/or seats are ground, measure the installed height of springs. Make sure the measurement is taken from bottom of spring seat in cylinder head to the bottom surface of spring retainer. If spacers are installed, measure from the top of spacer. If height is greater than 42.86
mm (1-11/16 inches), install a 1.587 mm (1/16 inch) spacer in head counterbore. This should bring spring height back to normal 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch).(8) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
ROCKER ARM / ADJUSTER ASSEMBLY REMOVAL
(1) Remove cylinder head cover and gasket (Refer - ENGINE/CYLINDER HEAD/CYLINDER
to HEAD COVER(S) - REMOVAL).
(2) Remove the rocker arm bolts and pivots (Fig. 18). Place them on a bench in the same order as removed.
Fig.18RockerArms
1 - ROCKER ARMS 2 - CYLINDER HEAD
INSTALLATION
(1) Rotate the crankshaft until the “V8” mark lines up with the TDC mark on the timing chain case cover. This mark is located 147° ATDC from the No.1
firing position.(2) Install the push rods in the same order as
removed.
(3) Install rocker arm and pivot assemblies in the same order as removed. Tighten the rocker arm bolts to 28 N·m (21 ft. lbs.) torque.
CAUTION: DO NOT rotate or crank the engine dur- ing or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes).
(4) Install
cylinder head cover
to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
(Refer
ENGINE BLOCK CLEANING
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leakage.
INSPECTION
Examine block for cracks or fractures. The cylinder walls should be checked for out-of- round and taper. Refer to Honing Cylinder Bores in the Service Procedures portion of this Section.
Inspect the oil line plug, the oil line plug is located in the vertical passage at the rear of the block between the oil-to-filter and oil-from-filter passages (Fig. 19). Improper installation or missing plug could cause erratic, low, or no oil pressure.
The oil plug must come out the bottom. Use flat dowel, down the oil pressure sending unit hole from the top, to remove oil plug.
ENGINE - 5.9L
9 - 250
ENGINE BLOCK (Continued)(1) Remove oil pressure sending unit from back of
block.
(2) Insert a 3.175 mm (1/8 in.)
finish wire, or
equivalent, into passage.
(3) Plug should be 190.0 to 195.2 mm (7-1/2 to 7-11/16 in.) from machined surface of block (Fig. 19). If plug is too high, use a suitable flat dowel to posi- tion properly.
Fig.19OilLinePlug
1 - RIGHT OIL GALLERY 2 - CYLINDER BLOCK 3 - OIL FROM FILTER TO SYSTEM 4 - OIL TO FILTER 5 - FROM OIL PUMP 6 - CRANKSHAFT 7 - PLUG
(4) If plug is too low, remove oil pan and No. 4
main bearing cap. Use suitable flat dowel to position properly. Coat outside diameter of plug with Mopart Stud and Bearing Mount Adhesive. Plug should be 54.0 to 57.7 mm (2-1/8 to 2-5/16 in.) from bottom of the block.DR
CAMSHAFT & BEARINGS (IN BLOCK) REMOVAL—CAMSHAFT
NOTE: The camshaft has an integral oil pump and distributor drive gear (Fig. 20).
Fig.20CamshaftandSprocketAssembly
1 - THRUST PLATE 2 - OIL PUMP AND DISTRIBUTOR DRIVE GEAR INTEGRAL WITH CAMSHAFT 3 - CAMSHAFT SPROCKET
(1) Remove the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - REMOVAL).
(2) Remove the A/C Condenser (if equipped) (3) Remove the engine cover. (4) Remove intake manifold (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - REMOVAL).
(5) Remove cylinder head covers (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(6) Remove timing case cover
to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL) and timing chain (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).(Refer
(7) Remove rocker arms. (8) Remove push rods and tappets. Identify each
part so it can be installed in its original location.
(9) Remove distributor and lift out the oil pump
and distributor drive shaft.
(10) Remove camshaft thrust plate, note location of
oil tab (Fig. 21).
(11) Install a long bolt into front of camshaft to aid in removal of the camshaft. Remove camshaft, being careful not to damage cam bearings with the cam lobes.
INSTALLATION—CAMSHAFT
(1) Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 51 mm (2
inches) of its final position in cylinder block.(2) Install Camshaft Holder Tool C-3509 with
tongue back of distributor drive gear (Fig. 22).
DR CAMSHAFT & BEARINGS (IN BLOCK) (Continued)
ENGINE - 5.9L
9 - 251
(5) Install timing chain and gears (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).
(6) Measure camshaft end play (Refer to 9 - ENGINE - SPECIFICATIONS). If not within limits install a new thrust plate.
(7) Each tappet reused must be installed in the same position from which it was removed. When camshaft is replaced, all of the tappets must be replaced.
(8) Install distributor and distributor drive shaft. (9) Install push rods and tappets. (10) Install rocker arms. (11) Install
to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
timing case cover
(Refer
(12) Install cylinder head covers (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
(13) Install intake manifold (Refer to 9 - ENGINE/ INSTALLA-
MANIFOLDS/INTAKE MANIFOLD - TION).
(14) Install the engine cover. (15) Install the A/C Condenser (if equipped) (16) Install the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION).
(17) Start engine check for leaks.
CONNECTING ROD BEARINGS STANDARD PROCEDURE - CONNECTING ROD BEARING FITTING
Fit all rods on a bank until completed. DO NOT alternate from one bank to another, because connect- ing rods and pistons are not interchangeable from one bank to another.
The bearing caps are not
should be marked at removal assembly.
interchangeable and to ensure correct
Each bearing cap has a small V-groove across the parting face. When installing the lower bearing shell, be certain that the V-groove in the shell is in line with the V-groove in the cap. This provides lubrica- tion of the cylinder wall in the opposite bank.
The bearing shells must be installed so that the tangs are in the machined grooves in the rods and caps.
Limits of taper or out-of-round on any crankshaft journals should be held to 0.025 mm (0.001 in.). Bearings are available in 0.025 mm (0.001 in.), 0.051
mm (0.002 in.), 0.076 mm (0.003 in.), 0.254 mm (0.010 in.) and 0.305 mm (0.012 in.) undersize. Install the bearings in pairs. DO NOT use a new bearing half with an old bearing half. DO NOT file the rods or bearing caps.Fig.21TimingChainOil
1 - THRUST PLATE FRONT SIDE 2 - CHAIN OIL TAB 3 - THRUST PLATE REAR SIDE
Fig.22CamshaftHoldingToolC-3509(Installed
Position)
1 - SPECIAL TOOL C-3509
2 - DRIVE GEAR 3 - DISTRIBUTOR LOCK BOLT(3) Hold tool in position with a distributor lock- plate bolt. This tool will restrict camshaft from being pushed in too far and prevent knocking out the welch plug in rear of cylinder block. Tool should remain installed until the camshaft and crankshaft sprockets and timing chain have been installed. (4) Install camshaft thrust plate and chain oil tab. Make sure tang enters lower right hole in thrust plate. Tighten bolts to 24 N·m (210 in. lbs.) torque. Top edge of tab should be flat against thrust plate in order to catch oil for chain lubrication.
9 - 252
ENGINE - 5.9L
CRANKSHAFT DESCRIPTION
The crankshaft (Fig. 23) is of a cast nodular steel splayed type design, with five main bearing journal- s.The crankshaft is located at the bottom of the engine block and is held in place with five main bear- ing caps. The number 3 counterweight is the location for journal size identification.
Fig.23CrankshaftwithJournalSizeIdentification OPERATION
The crankshaft transfers force generated by com- bustion within the cylinder bores to the flywheel or flexplate.
REMOVAL
NOTE: This procedure can be done in vehicle. How- ever the transmission must be removed first.
(1) If crankshaft is to be removed while engine is in vehicle remove the transmission. Refer to 21 - TRANSMISSION/TRANSAXLE.
(2) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(3) Remove the oil pump from the rear main bear- ing cap (Refer to 9 - ENGINE/LUBRICATION/OIL PUMP - REMOVAL).
(4) Remove the vibration damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL).
(5) Remove the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
(6) Identify rod bearing caps before removal.
Remove rod bearing caps with bearings.
DR
CAUTION: Support crankshaft before removing main bearing caps. failure to do so will allow the crankshaft to fall damaging the crankshaft.
(7) Using a suitable jack, support the crankshaft. (8) Identify main bearing caps before removal. Remove main bearing caps and bearings one at a time.
(9) Lower the crankshaft out of the block. (10) Remove and discard the crankshaft rear oil
(11) Remove and discard the front crankshaft oil
seals.
seal.
INSTALLATION
(1) Clean Gasket Maker residue and sealant from the cylinder block and rear cap mating surface. Do this before applying the Mopart Gasket Maker and the installation of rear cap.
(2) Lightly oil the new upper seal lips with engine
oil.
oil.
(3) Install the new upper rear bearing oil seal with the white paint facing towards the rear of the engine. (4) Position the crankshaft into the cylinder block. (5) Lightly oil the new lower seal lips with engine
(6) Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine.
(7) Apply 5 mm (0.20 in) drop of Mopart Gasket Maker, or equivalent, on each side of the rear main bearing cap (Fig. 24). DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assem- ble bearing cap to cylinder block immediately after sealant application.
Fig.24SealantApplicationtoBearingCap
1 - MOPART GASKET MAKER 5 mm (0.20 IN.) ON BOTH SIDES OF REAR MAIN CAP
DR CRANKSHAFT (Continued)
(8) To align the bearing cap, use cap slot, align- ment dowel and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than 2 times for proper engagement.
(9) Clean and oil all cap bolts. Install all main bearing caps. Install all cap bolts and alternately tighten to 115 N·m (85 ft. lbs.) torque.
(10) Install oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(11) Install the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
(12) Install the vibration damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).
(13) Position the connecting rods onto the crank- shaft and install the rod bearing caps. Tighten the nuts to 61 N·m (45 ft. lbs.).
(14) Apply Mopart Silicone Rubber Adhesive Seal- ant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing (Fig. 25). Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess seal- ant off the oil pan seal groove.
(15) Install new front crankshaft oil seal (Refer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - FRONT - INSTALLATION).
(16) Immediately install the oil pan (Refer to 9 - INSTALLA-
ENGINE/LUBRICATION/OIL PAN - TION).
Fig.25ApplySealanttoBearingCaptoBlockJoint 1 - MOPAR SILICONE RUBBER ADHESIVE SEALANT NOZZLE TIP 2 - SEALANT APPLIED 3 - CYLINDER BLOCK 4 - REAR MAIN BEARING CAP
(17) If the transmission was removed, install the transmission. Refer to 21 - TRANSMISSION/TRANS- AXLE.
ENGINE - 5.9L
9 - 253
CRANKSHAFT MAIN BEARINGS DESCRIPTION
Main bearings (Fig. 26) are located in the cylinder block. One half of the main bearing is located in the crankshaft main bore the other half of the matching bearing is located in the main bearing cap. there are five main bearings. Number three main bearing is flanged, this flange controls crankshaft thrust.
Fig.26MainBearingOrientation
OPERATION
The main bearings encircle the crankshaft main bearing journals, this aligns the crankshaft to the centerline of the engine and allows the crankshaft to turn without wobbling or shaking therefore eliminat- ing vibration. The main bearings are available in standard and undersizes.
STANDARD PROCEDURE—CRANKSHAFT MAIN BEARING FITTING
Bearing caps are not interchangeable and should be marked at removal to ensure correct assembly. Upper and lower bearing halves are NOT inter- changeable. Lower main bearing halves of No.2 and 4
are interchangeable.Upper and lower No.3 bearing halves are flanged to carry the crankshaft thrust loads. They are NOT interchangeable with any other bearing halves in the engine (Fig. 27). Bearing shells are available in stan- dard and the following undersizes: Never install an undersize bearing that will reduce clearance below specifications.
ENGINE - 5.9L
9 - 254
CRANKSHAFT MAIN BEARINGS (Continued)MainBearingUndersizeAvailabilityList
† 0.25 mm (0.001 inch) † 0.051 mm (0.002 inch) † 0.076 mm (0.003 inch) † 0.254 mm (0.010 inch) † 0.305 mm (0.012 inch)
DR
Fig.28UpperMainBearingRemovaland
InstallationwithToolC-3059
1 - SPECIAL TOOL C-3059
2 - BEARING 3 - SPECIAL TOOL C-3059
4 - BEARINGFig.27MainBearing
REMOVAL
(1) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(2) Remove the oil pump from the rear main bear- ing cap (Refer to 9 - ENGINE/LUBRICATION/OIL PUMP - REMOVAL).
(3) Identify bearing caps before removal. Remove
bearing caps one at a time.
(4) Remove upper half of bearing by inserting Crankshaft Main Bearing Remover/Installer Tool C-3059 into the oil hole of crankshaft (Fig. 28).
(5) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
INSTALLATION
Only one main bearing should be selectively fitted while all other main bearing caps are properly tight- ened. All bearing capbolts removed during service procedures are to be cleaned and oiled before instal- lation.
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
(1) Start bearing in place, and insert Crankshaft Main Bearing Remover/Installer Tool C-3059 into oil hole of crankshaft (Fig. 28).
(2) Slowly rotate crankshaft counterclockwise slid-
ing the bearing into position. Remove Tool C-3059.
(3) Install the bearing caps. Clean and oil the bolts. Tighten the capbolts to 115 N·m (85 ft. lbs.) torque.
(4) Install the oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(5) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
(6) Start engine check for leaks.
CRANKSHAFT OIL SEAL - FRONT DESCRIPTION
The crankshaft front seal is a one piece viton seal with a steel housing. The front seal is located in the engine front cover.
OPERATION
The crankshaft seals prevent oil from leaking from around the crankshaft, either from the rear of the engine or from the engine front cover.
REMOVAL
The oil seal can be replaced without removing the timing chain cover, provided that the cover is not misaligned.
(1) Disconnect the negative cable from the battery. (2) Remove vibration damper to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL).
(Refer
(3) If front seal is suspected of leaking, check front oil seal alignment to crankshaft. The seal installa- tion/alignment Tool 6635, should fit with minimum interference. If tool does not fit, the cover must be removed and installed properly.
DR CRANKSHAFT OIL SEAL - FRONT (Continued)
(4) Place a suitable tool behind the lips of the oil seal to pry the oil seal outward. Be careful not to damage the crankshaft seal bore of cover.
INSTALLATION
ENGINE - 5.9L
9 - 255
(1) Place the smaller diameter of the oil seal over Front Oil Seal Installation Tool 6635 (Fig. 29). Seat the oil seal in the groove of the tool.
(2) Position the seal and tool onto the crankshaft
(Fig. 30).
(3) Using the vibration damper bolt, tighten the bolt to draw the seal into position on the crankshaft (Fig. 31).
(4) Remove the vibration damper bolt and seal
installation tool.
damper.
(5) Inspect
the
seal
flange
on the vibration
(6) Install
the vibration damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).
(7) Connect the negative cable to the battery.
Fig.30PositionToolandSealontoCrankshaft
1 - SPECIAL TOOL 6635
2 - OIL SEAL 3 - TIMING CHAIN COVERFig.29PlacingOilSealonInstallationTool6635
1 - CRANKSHAFT FRONT OIL SEAL 2 - INSTALL THIS END INTO SPECIAL TOOL 6635
CRANKSHAFT OIL SEAL - REAR DESCRIPTION
The crankshaft rear seal is a two piece viton seal. One part of the two piece rear seal is located in a slot in the cylinder block oppsite the crankshaft main bearing cap, the second part of the two piece seal is located in the main bearing cap itself.
OPERATION
The crankshaft seals prevent oil from leaking from around the crankshaft, either from the rear of the engine or from the engine front cover.
Fig.31InstallingOilSeal
1 - SPECIAL TOOL 6635
2 - TIMING CHAIN COVERREMOVAL
The service seal is a two piece, Viton seal. The upper seal half can be installed with crankshaft removed from engine or with crankshaft installed. When a new upper seal is installed, install a new
ENGINE - 5.9L
9 - 256
CRANKSHAFT OIL SEAL - REAR (Continued)lower seal. The lower seal half can be installed only with the rear main bearing cap removed.
UPPER SEAL —CRANKSHAFT REMOVED
(1) Remove the crankshaft (Refer to 9 - ENGINE/ ENGINE BLOCK/CRANKSHAFT - REMOVAL). Dis- card the old upper seal.
UPPER SEAL—CRANKSHAFT INSTALLED
DR
bearing cap (Fig. 32). DO NOT over-apply sealant or allow the sealant to contact the rubber seal. Assem- ble bearing cap to cylinder block immediately after sealant application.
(1) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(2) Remove the oil pump (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - REMOVAL).
(3) Remove the rear main bearing cap. Remove
and discard the old lower oil seal.
(4) Carefully remove and discard the old upper oil
seal.
LOWER SEAL
(1) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(2) Remove the oil pump (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - REMOVAL).
(3) Remove the rear main bearing cap and discard
the old lower seal.
INSTALLATION
The service seal is a two piece, Viton seal. The upper seal half can be installed with crankshaft removed from engine or with crankshaft installed. When a new upper seal is installed, install a new lower seal. The lower seal half can be installed only with the rear main bearing cap removed.
UPPER SEAL —CRANKSHAFT REMOVED
(1) Clean the cylinder block rear cap mating sur- face. Be sure the seal groove is free of debris. Check for burrs at the oil hole on the cylinder block mating surface to rear cap.
(2) Lightly oil the new upper seal lips with engine
oil.
(3) Install the new upper rear bearing oil seal with the white paint facing toward the rear of the engine. (4) Position the crankshaft into the cylinder block. (5) Lightly oil the new lower seal lips with engine oil. (6) Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine.
(7) Apply 5 mm (0.20 in.) drop of Mopart Gasket Maker, or equivalent, on each side of the rear main
Fig.32SealantApplicationtoBearingCap 1 - MOPAR SILICONE RUBBER ADHESIVE SEALANT SLOTS 2 - MOPART GASKET MAKER (OR EQUIVALENT) 3 - CAP ALIGNMENT SLOT 4 - REAR MAIN BEARING CAP
(8) To align the bearing cap, use cap slot, align- ment dowel, and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than two times for proper engagement.
(9) Clean and oil all cap bolts. Install all main bearing caps. Install all cap bolts and alternately tighten to 115 N·m (85 ft. lbs.) torque.
(10) Install oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(11) Apply Mopart GEN II Silicone Rubber Adhe- sive Sealant, or equivalent, at bearing cap-to-block joint to provide cap to block and oil pan sealing (Fig. 33). Apply enough sealant so that a small amount is squeezed out. Withdraw nozzle and wipe excess seal- ant off the oil pan seal groove.
(12) Install new front crankshaft oil seal (Refer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - FRONT - INSTALLATION).
(13) Immediately install the oil pan (Refer to 9 - INSTALLA-
ENGINE/LUBRICATION/OIL PAN - TION).
DR CRANKSHAFT OIL SEAL - REAR (Continued)
ENGINE - 5.9L
9 - 257
(7) Install the rear main bearing cap with cleaned and oiled cap bolts. Alternately tighten ALL cap bolts to 115 N·m (85 ft. lbs.) torque.
(8) Install oil pump (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PUMP - INSTALLATION).
(9) Apply Mopart GEN II Silicone Rubber Adhe- sive Sealant, or equivalent, at bearing cap-to-block joint to provide cap-to-block and oil pan sealing (Fig. 33). Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess seal- ant off the oil pan seal groove.
(10) Immediately install the oil pan (Refer to 9 - INSTALLA-
ENGINE/LUBRICATION/OIL PAN - TION).
LOWER SEAL
(1) Clean the rear main cap mating surfaces
including the oil pan gasket groove.
(2) Carefully install a new upper seal. Refer to
UPPER SEAL—CRANKSHAFT INSTALLED.
(3) Lightly oil the new lower seal lips with engine
oil.
(4) Install a new lower seal in bearing cap with
the white paint facing the rear of engine.
(5) Apply 5 mm (0.20 in.) drop of Mopart Gasket Maker, or equivalent, on each side of the rear main bearing cap (Fig. 32). DO NOT over-apply sealant or allow the sealant to contact the rubber seal. Assem- ble bearing cap to cylinder block immediately after sealant application.
(6) To align the bearing cap, use cap slot, align- ment dowel, and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than two times for proper engagement.
