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(7) Install the rear main bearing cap with cleaned and oiled cap bolts. Alternately tighten the 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. Apply enough sealant so that 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).
Fig.33ApplySealanttoBearingCap-to-BlockJoint 1 - MOPAR SILICONE RUBBER ADHESIVE SEALANT NOZZLE TIP 2 - SEALANT APPLIED 3 - CYLINDER BLOCK 4 - REAR MAIN BEARING CAP
UPPER SEAL—CRANKSHAFT INSTALLED
(1) Clean the cylinder block mating surfaces before oil seal installation. 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. To allow ease of installation of the seal, loosen at least the two main bearing caps forward of the rear bearing cap.
(3) Rotate the new upper seal into the cylinder block, being careful not to shave or cut the outer sur- face of the seal. To ensure proper installation, use the installation tool provided with the kit. Install the new seal with the white paint facing toward the rear of the engine.
(4) Install the new lower rear bearing oil seal into the bearing cap with the white paint facing toward the rear of the 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. Be sure the white paint faces toward the rear of the engine.
(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.
9 - 258
ENGINE - 5.9L
DR
DISTRIBUTOR BUSHING REMOVAL
CAUTION: This procedure MUST be followed when installing a new bushing or seizure to shaft may occur.
(1) Remove distributor (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/DISTRIBUTOR - REMOVAL). (2) Remove the intake manifold (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE REMOVAL).
(3) Insert Distributor Drive Shaft Bushing Puller Tool C-3052 into old bushing and thread down until a tight fit is obtained (Fig. 34).
(4) Hold puller screw and tighten puller nut until
bushing is removed.
Fig.36BurnishingDistributorDriveshaftBushing 1 - SPECIAL TOOL C-3053
2 - BUSHING(4) Install
the intake manifold (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE INSTALLATION).
(5) Install the distributor (Refer to 8 - ELECTRI-
CONTROL/DISTRIBUTOR
CAL/IGNITION INSTALLATION).
Fig.34DistributorDriveshaftBushingRemoval
1 - SPECIAL TOOL C-3052
2 - BUSHINGINSTALLATION
(1) Slide new bushing over burnishing end of Dis- tributor Drive Shaft Bushing Driver/Burnisher Tool C-3053. Insert the tool and bushing into the bore.
(2) Drive bushing and tool into position, using a
hammer (Fig. 35).
HYDRAULIC LIFTERS DIAGNOSIS AND TESTING—HYDRAULIC TAPPETS
Before disassembling any part of the engine to cor- rect tappet noise, check the oil pressure. If vehicle has no oil pressure gauge, install a reliable gauge at the pressure sending-unit. The pressure should be between 207-552 kPa (30-80 psi) at 3,000 RPM.
level, check dipstick. The oil
Check the oil level after the engine reaches normal operating temperature. Allow 5 minutes to stabilize oil in the pan should never be above the FULL mark or below the ADD OIL mark on dipstick. Either of these two con- ditions could be responsible for noisy tappets.
level
Fig.35DistributorDriveshaftBushingInstallation 1 - SPECIAL TOOL C-3053
2 - BUSHING(3) As the burnisher is pulled through the bushing, the bushing is expanded tight in the block and bur- nished to correct size (Fig. 36). DO NOT ream this bushing.
OIL LEVEL
HIGH
If oil level is above the FULL mark, it is possible for the connecting rods to dip into the oil. With the engine running, this condition could create foam in the oil pan. Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to lose length and allow valves to seat noisily.
LOW
Low oil level may allow oil pump to take in air. When air is fed to the tappets, they lose length, which allows valves to seat noisily. Any leaks on
DR HYDRAULIC LIFTERS (Continued)
intake side of oil pump through which air can be drawn will create the same tappet action. Check the lubrication system from the intake strainer to the pump cover, including the relief valve retainer cap. When tappet noise is due to aeration, it may be intermittent or constant, and usually more than one tappet will be noisy. When oil level and leaks have been corrected, operate the engine at fast idle. Run engine for a sufficient time to allow all of the air inside the tappets to be bled out.
TAPPET NOISE DIAGNOSIS
(1) To determine source of tappet noise, operate
engine at idle with cylinder head covers removed.
(2) Feel each valve spring or rocker arm to detect noisy tappet. The noisy tappet will cause the affected spring and/or rocker arm to vibrate or feel rough in operation.
NOTE: Worn valve guides or cocked springs are sometimes mistaken for noisy tappets. If such is the case, noise may be dampened by applying side thrust on the valve spring. If noise is not apprecia- bly reduced, it can be assumed the noise is in the tappet. Inspect the rocker arm push rod sockets and push rod ends for wear.
(3) Valve tappet noise ranges from light noise to a heavy click. A light noise is usually caused by exces- sive leak-down around the unit plunger, or by the plunger partially sticking in the tappet body cylinder. The tappet should be replaced. A heavy click is caused by a tappet check valve not seating, or by for- eign particles wedged between the plunger and the tappet body. This will cause the plunger to stick in the down position. This heavy click will be accompa- nied by excessive clearance between the valve stem and rocker arm as valve closes. In either case, tappet assembly should be removed for inspection and clean- ing.
(4) The valve train generates a noise very much like a light tappet noise during normal operation. Care must be taken to ensure that tappets are mak- ing the noise. If more than one tappet seems to be noisy, it’s probably not the tappets.
LEAK-DOWN TEST
After cleaning and inspection, test each tappet for specified leak-down rate tolerance to ensure zero-lash operation (Fig. 37).
Swing the weighted arm of the hydraulic valve tap- pet tester away from the ram of the Universal Leak- Down Tester.
(1) Place a 7.925-7.950 mm (0.312-0.313 inch) diameter ball bearing on the plunger cap of the tap- pet.
ENGINE - 5.9L
9 - 259
(2) Lift the ram and position the tappet (with the
ball bearing) inside the tester cup.
(3) Lower the ram, then adjust the nose of the ram until it contacts the ball bearing. DO NOT tighten the hex nut on the ram.
(4) Fill the tester cup with hydraulic valve tappet
test oil until the tappet is completely submerged.
(5) Swing the weighted arm onto the push rod and pump the tappet plunger up and down to remove air. When the air bubbles cease, swing the weighted arm away and allow the plunger to rise to the normal position.
(6) Adjust the nose of the ram to align the pointer with the SET mark on the scale of the tester and tighten the hex nut.
(7) Slowly swing the weighted arm onto the push
rod.
(8) Rotate the cup by turning the handle at the base of the tester clockwise one revolution every 2
seconds.(9) Observe the leak-down time interval from the instant the pointer aligns with the START mark on the scale until the pointer aligns with the 0.125
mark. A normally functioning tappet will require 20-110 seconds to leak-down. Discard tappets with leak-down time interval not within this specification.Fig.37Leak-DownTester
1 - POINTER 2 - WEIGHTED ARM 3 - RAM 4 - CUP 5 - HANDLE 6 - PUSH ROD
REMOVAL
(1) Remove the air cleaner assembly and air in-let
hose.
(2) Remove cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
DR
PISTON & CONNECTING ROD DESCRIPTION
The pistons are made of aluminum and have three ring grooves, the top two grooves are for the compres- sion rings and the bottom groove is for the oil control ring. The connecting rods are forged steel and are coined prior to heat treat. The piston pins are press fit.
STANDARD PROCEDURE - PISTON FITTING
Piston and cylinder wall must be clean and dry. Specified clearance between the piston and the cylin- der wall is 0.013-0.038 mm (0.0005-0.0015 inch) at 21°C (70°F).
Piston diameter should be measured at the top of skirt, 90° to piston pin axis. Cylinder bores should be measured halfway down the cylinder bore and trans- verse to the engine crankshaft center line.
Pistons and cylinder bores should be measured at
normal room temperature, 21°C (70°F).
Check the pistons for taper and elliptical shape before they are fitted into the cylinder bore (Fig. 38).
ENGINE - 5.9L
9 - 260
HYDRAULIC LIFTERS (Continued)(3) Remove rocker assembly and push rods (Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER ARM / ADJUSTER ASSY - REMOVAL). Identify push rods to ensure installation in original locations.
(4) Remove intake manifold (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - REMOVAL).
(5) Remove yoke retainer and aligning yokes. (6) Slide Hydraulic Tappet Remover/Installer Tool C-4129-A through opening in cylinder head and seat tool firmly in the head of tappet.
(7) Pull tappet out of bore with a twisting motion. If all tappets are to be removed, identify tappets to ensure installation in original location.
(8) If the tappet or bore in cylinder block is scored, scuffed, or shows signs of sticking, ream the bore to next oversize. Replace with oversize tappet.
CLEANING
Clean tappet with a suitable solvent. Rinse in hot water and blow dry with a clean shop rag or com- pressed air.
INSTALLATION
(1) Lubricate tappets with Mopart Engine Oil
Supplement or equivalent.
(2) Install tappets and push rods in their original positions. Ensure that the oil feed hole in the side of the tappet body faces up (away from the crankshaft). (3) Install aligning yokes with ARROW toward
camshaft.
(4) Install yoke retainer. Tighten the bolts to 23
N·m (200 in. intake manifold (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI- FOLD - INSTALLATION).lbs.) torque. Install
(5) Install rocker arms (Refer to 9 - ENGINE/CYL- INDER HEAD/ROCKER ARM / ADJUSTER ASSY - INSTALLATION).
(6) Install
cylinder head cover
to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
(Refer
(7) Install air cleaner assembly and air in-let hose. (8) Start and operate engine. Warm up to normal
operating temperature.
CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all hydraulic tappets have filled with oil and have become quiet.
1 - 49.53 mm (1.95 IN.)
Fig.38PistonMeasurements
DR PISTON & CONNECTING ROD (Continued)
PISTON MEASUREMENT CHART
PISTON
A DIA = PISTON
SIZE
DIAMETER
BORE
DIAMETER
MIN. mm (in.)
—
MAX. mm (in.)
—
MIN. mm (in.)
—
MAX.
mm (in.)
—
101.580
101.592
101.605
101.618
(3.9992)
(3.9997)
(4.0002)
(4.0007)
101.592
101.605
101.618
101.630
(3.9997)
(4.0002)
(4.0007)
(4.0012)
101.605
101.618
101.630
101.643
(4.0002)
(4.0007)
(4.0012)
(4.0017)
—
—
—
—
DESCRIPTION
SPECIFICATION
PISTON PIN BORE
25.007 - 25.015 mm (.9845 - .9848 in.)
RING GROOVE
HEIGHT
OIL RAIL
COMPRESSION RAIL
4.033 - 4.058 mm (.1588 - .1598 in.) 1.529 - 1.554 mm
(.0602 - .0612 in.)
TOTAL FINISHED
470.8 ± 2 grams
WEIGHT
(16.607 ± .0706 ounces)
REMOVAL
(1) Remove the engine from the vehicle (Refer to 9
- ENGINE - REMOVAL).
(2) Remove the cylinder head (Refer ENGINE/CYLINDER HEAD - REMOVAL).
to 9 -
(3) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(4) Remove top ridge of cylinder bores with a reli- able ridge reamer before removing pistons from cyl- inder block. Be sure to keep tops of pistons covered during this operation.
(5) Be sure each connecting rod and connecting rod cap is identified with the cylinder number. Remove connecting rod cap. Install connecting rod bolt guide set on connecting rod bolts.
ENGINE - 5.9L
9 - 261
(6) Pistons and connecting rods must be removed from top of cylinder block. When removing the assemblies from the engine, rotate crankshaft so that the connecting rod is centered in cylinder bore and at BDC. Be careful not to nick crankshaft journals. (7) After removal, install bearing cap on the mat-
ing rod.
CLEANING
Clean the piston and connecting rod assembly
using a suitable solvent.
INSPECTION
Check the connecting rod journal
for excessive wear, taper and scoring (Refer to 9 - ENGINE/EN- GINE BLOCK/CONNECTING ROD BEARINGS - STANDARD PROCEDURE).
Check the connecting rod for signs of twist or bend-
ing.
Check the piston for taper and elliptical shape before it is fitted into the cylinder bore (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON & CONNECT- ING ROD - STANDARD PROCEDURE).
Check the piston for scoring, or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration.
INSTALLATION
(1) Be sure that compression ring gaps are stag- gered so that neither is in line with oil ring rail gap. (2) Before installing the ring compressor, be sure the oil ring expander ends are butted and the rail gaps located properly (Fig. 39).
Fig.39ProperRingInstallation
1 - OIL RING SPACER GAP 2 - SECOND COMPRESSION RING GAP OIL RING RAIL GAP (TOP) 3 - OIL RING RAIL GAP (BOTTOM) 4 - TOP COMPRESSION RING GAP
ENGINE - 5.9L
9 - 262
PISTON & CONNECTING ROD (Continued)DR
(b) Install the second compression rings using Installation Tool C-4184. The compression rings must be installed with the identification mark face up (toward top of piston) and chamfer facing down. An identification mark on the ring is a drill point, a stamped letter “O”, an oval depression, or the word “TOP” (Fig. 40) (Fig. 42).
(c) Using a ring installer, install the top com- pression ring with the chamfer facing up (Fig. 41) (Fig. 42). An identification mark on the ring is a drill point, a stamped letter “O”, an oval depression or the word “TOP” facing up.
(d) Measure side clearance between piston ring and ring land. Clearance should be 0.074-0.097 mm (0.0029-0.0038 in.) for the compression rings. The steel rail oil ring should be free in groove, but should not exceed 0.246 mm (0.0097 in.) side clearance.
(e) Pistons with insufficient, or excessive, side
clearance should be replaced.
(3) Immerse the piston head and rings in clean engine oil. Slide Piston Ring Compressor Tool C-385
over the piston and tighten with the special wrench (part of Tool C-385). Be sure position of rings does not change during this operation.(4) Install connecting rod bolt protectors on rod bolts. The long protector should be installed on the numbered side of the connecting rod.
(5) Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Be sure connecting rod and cylinder bore number are the same. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on crankshaft journal.
(7) The notch, or groove, on top of piston must be pointing toward front of engine. The larger chamfer of the connecting rod bore must be installed toward crankshaft journal fillet.
(8) Install rod caps. Be sure connecting rod, con- necting rod cap, and cylinder bore number are the same. Install nuts on cleaned and oiled rod bolts and tighten nuts to 61 N·m (45 ft. lbs.) torque.
(9) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION). the cylinder head (Refer
(10) Install
to 9 -
ENGINE/CYLINDER HEAD - INSTALLATION).
(11) Install the engine into the vehicle (Refer to 9 -
ENGINE - INSTALLATION).
PISTON RINGS STANDARD PROCEDURE - PISTON RING FITTING
Fig.40SecondCompressionRingIdentification
(Typical)
1 - SECOND COMPRESSION RING (BLACK CAST IRON) 2 - CHAMFER 3 - TWO DOTS
(1) Measurement of end gaps:
(a) Measure piston ring gap 2 in. from bottom of cylinder bore. An inverted piston can be used to push the rings down to ensure positioning rings squarely in the cylinder bore before measuring.
(b) Insert feeler gauge in the gap. The top com- pression ring gap should be between 0.254-0.508
mm (0.010-0.020 in.). The second compression ring gap 0.508-0.762 mm (0.020-0.030 in.). The oil ring gap should be 0.254- 1.270 mm (0.010-0.050 in.).between
should
be
(c) Rings with insufficient end gap may be prop- erly filed to the correct dimension. Rings with excess gaps should not be used. (2) Install rings, and confirm ring side clearance: (a) Install oil rings being careful not to nick or scratch the piston. Install the oil control rings accord- ing to instructions in the package. It is not necessary to use a tool to install the upper and lower rails. Insert oil rail spacer first, then side rails.
Fig.41TopCompressionRingIdentification(Typical) 1 - TOP COMPRESSION RING (GRAY IN COLOR) 2 - CHAMFER 3 - ONE DOT
(3) Orient the rings:
(a) Arrange top compression ring 90° counter-
clockwise from the oil ring rail gap (Fig. 43).
DR PISTON RINGS (Continued)
ENGINE - 5.9L
9 - 263
(6) Install Special Tool 1026 Three Jaw Puller onto
the vibration damper (Fig. 44).
Fig.42CompressionRingChamferLocation(Typical) 1 - CHAMFER 2 - TOP COMPRESSION RING 3 - SECOND COMPRESSION RING 4 - PISTON 5 - CHAMFER
(b) Arrange second compression ring 90° clock-
wise from the oil ring rail gap (Fig. 43).
Fig.43ProperRingInstallation
1 - OIL RING SPACER GAP 2 - SECOND COMPRESSION RING GAP OIL RING RAIL GAP (TOP) 3 - OIL RING RAIL GAP (BOTTOM) 4 - TOP COMPRESSION RING GAP
VIBRATION DAMPER REMOVAL
(1) Disconnect the battery negative cable. (2) Remove the cooling system fan (Refer to 7 - VISCOUS
DRIVE
COOLING/ENGINE/FAN CLUTCH - REMOVAL).
(3) Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(4) Remove vibration damper bolt and washer from
end of crankshaft.
crankshaft nose.
(5) Position Special Tool 8513 Insert
into the
Fig.44VibrationDamperRemoval
1 - SPECIAL TOOL 8513 INSERT 2 - SPECIAL TOOL 1026
(7) Pull vibration damper off of the crankshaft.
INSTALLATION
CAUTION: Thoroughly remove any contaminants from the crankshaft nose and the vibration damper bore. Failure to do so can cause sever damage to the crankshaft.
(1) Position the vibration damper onto the crankshaft. (2) Place installing tool, part of Puller Tool Set C-3688 in position and press the vibration damper onto the crankshaft (Fig. 45).
Fig.45VibrationDamperInstallation
1 - SPECIAL TOOL C-3688
(3) Install the crankshaft bolt and washer. Tighten
the bolt to 244 N·m (180 ft. lbs.) torque.
(4) Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(5) Position the fan shroud and install the bolts. Tighten the retainer bolts to 11 N·m (95 in. lbs.) torque. (6) Install the cooling fan (Refer to 7 - COOLING/ ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION).
(7) Connect the battery negative cable.
9 - 264
ENGINE - 5.9L
FRONT MOUNT REMOVAL
2WD
(1) Disconnect the negative cable from the battery.
CAUTION: Remove the viscous fan before raising engine. Failure to do so may cause damage to the fan blade, fan clutch and fan shroud.
(2) Remove the viscous fan (Refer to 7 - COOL- ING/ENGINE/FAN DRIVE VISCOUS CLUTCH - REMOVAL).
(3) Raise the vehicle. (4) Remove the engine oil filter. (5) Remove the oil drain trough. (6) Support the engine with a suitable jack and a block of wood across the full width of the engine oil pan.
(7) Support the front axle with a suitable jack. (8) Remove the (4) bolts that attach the engine
mounts to the front axle.
(9) Remove the (3) bolts that attach the front axle
to the left engine bracket.
(10) Lower the front axle. (11) Remove the through bolts
DR
(12) Raise the engine far enough to be able to
remove the left and right engine mounts.
(13) Remove the (8) mount to engine attaching bolts (14) Remove the engine mounts.
4WD
(1) Disconnect the negative cable from the battery.
CAUTION: Remove the viscous fan before raising engine. Failure to do so may cause damage to the fan blade, fan clutch and fan shroud.
(2) Remove the viscous fan (Refer to 7 - COOL- ING/ENGINE/FAN DRIVE VISCOUS CLUTCH - REMOVAL).
(3) Raise the vehicle. (4) Remove the skid plate. (5) Remove the front crossmember. (6) Remove the engine oil filter. (7) Remove the oil drain trough. (8) Support the engine with a suitable jack and a block of wood across the full width of the engine oil pan.
(9) Support the front axle with a suitable jack. (10) Remove the (4) bolts that attach the engine
mounts to the front axle (Fig. 46).
Fig.46ENGINEINSULATORMOUNTS4X4
1 - RH INSULATOR TO AXLE BOLT 2 - NUT 3 - PINION SUPPORT MOUNT 4 - LH INSULATOR MOUNT
5 - LH INSULATOR TO AXLE BOLT 6 - FRONT AXLE 7 - NUT 8 - RH INSULATOR MOUNT
DR FRONT MOUNT (Continued)
ENGINE - 5.9L
9 - 265
(11) Remove the (3) bolts that attach the front axle
to the left engine bracket.
(12) Lower the front axle. (13) Remove the (6) through bolts (14) Raise the engine far enough to be able to remove the left (Fig. 47) and right (Fig. 48) engine mounts.
Fig.48ENGINESUPPORTRH4X4
1 - BOLT 2 - ENGINE SUPPORT
Fig.47ENGINESUPPORTBRACKET5.9L
1 - ENGINE SUPPORT BRACKET 2 - BOLT 3 - BOLT
(15) Remove the engine mounts.
INSTALLATION
2WD
NOTE: For mount to engine block and left engine bracket to front axle bolts, apply MoparT Lock and Seal Adhesive, Medium Strength Threadlocker.
(1) Install the right and left side engine mounts to the engine block with (8) bolts. Torque bolts to 54
N·m (40 ft. lbs.).(2) Insert the (2) through bolts into the right and left side engine mounts and loose assemble the two nuts onto the through bolts.
(3) Lower the engine until the through bolts rest
onto the slots in the frame brackets.
(4) Tighten the through bolt nuts to 94 N·m (70 ft.
lbs.).
(5) Install the oil drain trough. (6) Install the engine oil filter. (7) Lower the vehicle. (8) Install the viscous fan (Refer to 7 - COOLING/ ENGINE/FAN DRIVE VISCOUS CLUTCH - REMOVAL).
(9) Reconnect the negative battery cable.
4WD
NOTE: For mount to engine block and left engine bracket to front axle bolts, apply MoparT Lock and Seal Adhesive, Medium Strength Threadlocker.
(1) Install the right and left side engine mounts to
the front axle. Torque nuts to 94 N·m (70 ft. lbs.).
(2) Raise the front axle into the frame and install the left and right side through bolts. Torque nuts to 94 N·m (70 ft. lbs.).
(3) Insert the two upper through bolts into the right and left side engine mounts and loose assemble the two nuts onto the through bolts.
(4) Lower the engine until the left and right side engine brackets rest on the through bolts, and the lower engine bracket through holes align with the engine mounts, and the left engine bracket holes align with the front axle slots (Fig. 49).
(5) Loose assemble the (3) bolts that attach the
front axle to the left engine bracket.
ENGINE - 5.9L
9 - 266
FRONT MOUNT (Continued)DR
Fig.49ENGINEINSULATORMOUNTS4X4
1 - RH INSULATOR TO AXLE BOLT 2 - NUT 3 - PINION SUPPORT MOUNT 4 - LH INSULATOR MOUNT
5 - LH INSULATOR TO AXLE BOLT 6 - FRONT AXLE 7 - NUT 8 - RH INSULATOR MOUNT
(6) Loose assemble the lower through bolts. (7) Torque the nuts for the (4) through bolts to 101
N·m (75 ft. lbs.).
(8) Torque the (3) bolts that attach the front axle
to the left engine bracket to 101 N·m (75 ft. lbs.).
(9) Install the oil drain trough. (10) Install the engine oil filter. (11) Install the front crossmember. (12) Install the skid plate. (13) Lower the vehicle. (14) Install the viscous fan (Refer to 7 - COOL- ING/ENGINE/FAN DRIVE VISCOUS CLUTCH - REMOVAL).
(15) Reconnect the negative battery cable.
REAR MOUNT REMOVAL
(1) Raise the vehicle on a hoist. (2) Using a suitable jack, support transmission. (3) Remove the nuts from the transmission mount
(Fig. 50).
(4) Remove the two bolts that attach the transmis-
sion mount to the engine bracket.
Fig.50TRANSMISSIONMOUNT
1 - MOUNT 2 - CROSSMEMBER 3 - NUT 4 - BOLT
DR REAR MOUNT (Continued)
ENGINE - 5.9L
9 - 267
OPERATION
The pump draws oil through the screen and inlet tube from the sump at the rear of the oil pan. The oil is driven between the drive and idler gears and pump body, then forced through the outlet to the block. An oil gallery in the block channels the oil to the inlet side of the full flow oil filter. After passing through the filter element, the oil passes from the center outlet of the filter through an oil gallery that channels the oil up to the main gallery, which extends the entire length on the right side of the block. The oil then goes down to the No. 1 main bear- ing, back up to the left side of the block, and into the oil gallery on the left side of the engine.
Galleries extend downward from the main oil gal- lery to the upper shell of each main bearing. The crankshaft is drilled internally to pass oil from the main bearing journals to the connecting rod journals. Each connecting rod bearing has half a hole in it, oil passes through the hole when the rods rotate and the hole lines up, oil is then thrown off as the rod rotates. This oil throwoff lubricates the camshaft lobes, distributor drive gear, cylinder walls, and pis- ton pins.
The hydraulic valve tappets receive oil directly from the main oil gallery. The camshaft bearings receive oil from the main bearing galleries. The front camshaft bearing journal passes oil through the cam- shaft sprocket to the timing chain. Oil drains back to the oil pan under the No. 1 main bearing cap.
The oil supply for the rocker arms and bridged pivot assemblies is provided by the hydraulic valve tappets, which pass oil through hollow push rods to a hole in the corresponding rocker arm. Oil from the rocker arm lubricates the valve train components. The oil then passes down through the push rod guide holes and the oil drain-back passages in the cylinder head, past the valve tappet area, and then returns to the oil pan (Fig. 52).
(5) Raise the transmission enough to remove the
mount from the crossmember.
(6) Remove the mount.
INSTALLATION
NOTE: Threadlocking compound must be applied to the bolts before installation.
(1) Install the two bolts that attach the transmis-
sion mount to the transmission bracket.
(2) Torque the bolts to 61N·m (45 ft.lbs.) torque. (3) Lower the transmission so the transmission mount rests on the crossmember, and the studs of the transmission mount are aligned in the slots in the crossmember.
(4) Install the nuts onto the transmission mount
studs through the crossmember access slot. (5) Torque the nuts to 54N·m (40 ft. lbs.).
LUBRICATION DESCRIPTION
A gear-type positive displacement pump (Fig. 51) is mounted at the underside of the rear main bearing cap. The pump uses a pick-up tube and screen assembly to gather engine oil from the oil pan.
Fig.51PositiveDisplacementOilPump—Typical 1 - INNER ROTOR AND SHAFT 2 - BODY 3 - DISTRIBUTOR DRIVESHAFT (REFERENCE) 4 - COTTER PIN 5 - RETAINER CAP 6 - SPRING 7 - RELIEF VALVE 8 - LARGE CHAMFERED EDGE 9 - BOLT 10 - COVER 11 - OUTER ROTOR
ENGINE - 5.9L
9 - 268
LUBRICATION (Continued)DR
1 - OIL DEFLECTOR TAB 2 - BOLT 3 - ROCKER ARM PIVOT 4 - ROCKER ARM 5 - DRIP OILING FOR VALVE TIP 6 - CYLINDER HEAD BOSS 7 - TO MAIN BEARINGS 8 - TO CAMSHAFT BEARINGS 9 - ROCKER ARM 10 - HOLLOW PUSH ROD 11 - TAPPET 12 - TO CONNECTING ROD BEARINGS 13 - OIL INTAKE
Fig.52OilLubricationSystem
14 - OIL PUMP 15 - OIL FILTER 16 - CRANKSHAFT 17 - FROM OIL PUMP 18 - OIL TO FILTER 19 - OIL FROM FILTER TO SYSTEM 20 - PASSAGE TO CAMSHAFT REAR BEARING 21 - RIGHT OIL GALLERY 22 - PLUG 23 - OIL PASSAGE FOR OIL PRESSURE INDICATOR LIGHT 24 - OIL SUPPLY VIA HOLLOW PUSH ROD SUPPLY IS FROM OIL GALLERY METERED THROUGH HYDRAULIC TAPPET 25 - OIL SUPPLY FROM HOLLOW PUSH ROD
DR LUBRICATION (Continued) DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING—ENGINE OIL LEAKS
Begin with a through visual
inspection of the engine, particularly at the area of the suspected leak. If an oil leak source is not readily identifiable, the following steps should be followed:
(1) Do not clean or degrease the engine at this time because some solvents may cause rubber to swell, temporarily stopping the leak.
(2) Add an oil-soluble dye (use as recommended by manufacturer). Start the engine and let idle for approximately 15 minutes. Check the oil dipstick to be sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light source. (3) Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil leak. If the oil leak is found and identified, repair per service manual instructions.
(4) If dye is not observed, drive the vehicle at var- ious speeds for approximately 24km (15 miles), and repeat previous step.
(5) If the oil leak source is not positively identified at this time, proceed with the air leak detection test method as follows:
(6) Disconnect the breather cap to air cleaner hose at the breather cap end. Cap or plug breather cap nipple.
(7) Remove the PCV valve from the cylinder head
cover. Cap or plug the PCV valve grommet.
(8) Attach an air hose with pressure gauge and
regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to more than 20.6 kpa (3 PSI) of test pressure.
(9) Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus- pected source. Adjust the regulator to the suitable test pressure that provide the best bubbles which will pinpoint the leak source. If the oil leak is detected and identified, repair per service manual procedures.(10) If the leakage occurs at the rear oil seal area, refer to the section, Inspection for Rear Seal Area Leak.
(11) If no leaks are detected, turn off the air sup- ply and remove the air hose and all plugs and caps. Install the PCV valve and breather cap hose. Proceed to next step.
(12) Clean the oil off the suspect oil
leak area using a suitable solvent. Drive the vehicle at various speeds approximately 24 km (15 miles). Inspect the engine for signs of an oil leak by using a black light.
ENGINE - 5.9L
9 - 269
DIAGNOSIS AND TESTING—ENGINE OIL PRESSURE
(1) Remove oil pressure sending unit. (2) Install Oil Pressure Line and Gauge Tool C-3292. Start engine and record pressure. (Refer to 9
- ENGINE - SPECIFICATIONS).OIL STANDARD PROCEDURE - ENGINE OIL
OIL LEVEL INDICATOR (DIPSTICK)
The engine oil level indicator is located at the right
front of the engine, left of the generator (Fig. 53).
Fig.53OilLevelIndicatorLocation
1 - CYLINDER HEAD COVER 2 - ENGINE OIL FILL CAP 3 - DIPSTICK 4 - ENGINE OIL FILTER 5 - FILTER BOSS
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil, oil foaming and oil pressure loss can result.
To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick.
(1) Position vehicle on level surface. (2) With engine OFF, allow approximately ten min- utes for oil to settle to bottom of crankcase, remove engine oil dipstick.
(3) Wipe dipstick clean. (4) Install dipstick and verify it is seated in the
tube.
(5) Remove dipstick, with handle held above the
tip, take oil level reading.
ENGINE - 5.9L
9 - 270
OIL (Continued)(6) Add oil only if level is below the ADD mark on
dipstick.
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals described in the Maintenance Schedule. This infor- mation can be found in the owner’s manual.
TO CHANGE ENGINE OIL
DR
Run engine until achieving normal operating tem-
(1) Position the vehicle on a level surface and turn
(2) Hoist vehicle. (3) Remove oil fill cap. (4) Place a suitable drain pan under crankcase
perature.
engine off.
drain.
(5) Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged.
(6) Install drain plug in crankcase. (7) Change oil filter (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - REMOVAL).
(8) Lower vehicle and fill crankcase with specified type (Refer to LUBRICATION & MAINTENANCE/ FLUID TYPES - DESCRIPTION) and amount of engine oil (Refer to LUBRICATION & MAINTE- NANCE - SPECIFICATIONS).
(9) Install oil fill cap. (10) Start engine and inspect for leaks. (11) Stop engine and inspect oil level.
OIL FILTER REMOVAL
All engines are equipped with a high quality full- flow, disposable type oil filter. DaimlerChrysler Cor- poration recommends a Mopart or equivalent oil filter be used.
(1) Position a drain pan under the oil filter. (2) Using a suitable oil filter wrench loosen filter. (3) Rotate the oil filter counterclockwise to remove
it from the cylinder block oil filter boss (Fig. 54).
(4) When filter separates from adapter nipple, tip gasket end upward to minimize oil spill. Remove fil- ter from vehicle.
(5) With a wiping cloth, clean the gasket sealing
surface (Fig. 55) of oil and grime.
(6) Install new filter (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - INSTALLATION).
INSTALLATION
(1) Lightly lubricate oil filter gasket with engine
oil or chassis grease.
Fig.54OilFilterRemoval—Typical
1 - ENGINE OIL FILTER 2 - OIL FILTER WRENCH
(2) Thread filter onto adapter nipple. When gasket makes contact with sealing surface, (Fig. 55) hand tighten filter one full turn, do not over tighten.
(3) Add oil (Refer to 9 - ENGINE/LUBRICATION/
OIL - STANDARD PROCEDURE).
Fig.55OilFilterSealingSurface—Typical
1 - SEALING SURFACE 2 - RUBBER GASKET 3 - OIL FILTER
OIL PAN REMOVAL
(1) Disconnect the negative cable from the battery. (2) Remove engine oil dipstick. (3) Raise vehicle. (4) Drain engine oil. (5) Remove exhaust pipe. (6) Remove left engine to transmission strut. (7) Loosen the right side engine support bracket cushion thru-bolt nut and raise the engine slightly. Remove oil pan by sliding backward and out.
(8) Remove the one-piece gasket.
CLEANING
Clean the block and pan gasket surfaces.
DR OIL PAN (Continued)
ENGINE - 5.9L
9 - 271
Trim or remove excess sealant film in the rear main cap oil pan gasket groove. DO NOT remove the sealant inside the rear main cap slots.
If present, trim excess sealant from inside the
Clean oil pan in solvent and wipe dry with a clean
engine.
cloth.
Clean oil screen and pipe thoroughly in clean sol-
vent. Inspect condition of screen.
INSPECTION
Inspect oil drain plug and plug hole for stripped or
damaged threads. Repair as necessary.
Inspect oil pan mounting flange for bends or distor-
tion. Straighten flange, if necessary.
INSTALLATION
(1) Clean the block and pan gasket surfaces. (2) Trim or remove excess sealant film in the rear main cap oil pan gasket groove. DO NOT remove the sealant inside the rear main cap slots.
(3) If present, trim excess sealant from inside the
engine.
(4) Fabricate 4 alignment dowels from 5/16 x 1 1/2
inch bolts. Cut the head off the bolts and cut a slot into the top of the dowel. This will allow easier installation and removal with a screwdriver (Fig. 56).Fig.56FabricationofAlignmentDowels
1 - 5/16” X 11⁄2” BOLT 2 - DOWEL 3 - SLOT
Fig.57PositionofDowelsinCylinderBlock
1 - DOWEL 2 - DOWEL 3 - DOWEL 4 - DOWEL
(10) Remove the dowels. Install the remaining oil pan bolts. Tighten these bolts to 24 N·m (215 in. lbs.) torque.
(11) Lower the engine into the support cushion brackets and tighten the thru bolt nut to the proper torque.
(12) Install the drain plug. Tighten drain plug to
34 N·m (25 ft. lbs.) torque.
(13) Install the engine to transmission strut. (14) Install exhaust pipe. (15) Lower vehicle. (16) (17) Connect the negative cable to the battery. (18) Fill crankcase with oil to proper level.
Install dipstick.
(5) Install the dowels in the cylinder block (Fig.
57).
(6) Apply small amount of Mopart Silicone Rubber Adhesive Sealant, or equivalent in the corner of the cap and the cylinder block.
(7) Slide the one-piece gasket over the dowels and
(8) Position the oil pan over the dowels and onto
onto the block.
the gasket.
(9) Install the oil pan bolts. Tighten the bolts to 24
N·m (215 in. lbs.) torque.
9 - 272
ENGINE - 5.9L
OIL PUMP REMOVAL
DR
(1) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(2) Remove the oil pump from rear main bearing
cap.
DISASSEMBLY
(1) Remove the relief valve as follows:
(a) Remove cotter pin. Drill a 3.175 mm (1/8
inch) hole into the relief valve retainer cap and insert a self-threading sheet metal screw.(b) Clamp screw into a vise and while support- ing oil pump, remove cap by tapping pump body using a soft hammer. Discard retainer cap and remove spring and relief valve (Fig. 58).
Fig.58OilPressureReliefValve
1 - OIL PUMP ASSEMBLY 2 - COTTER PIN 3 - RELIEF VALVE 4 - RETAINER CAP 5 - SPRING
(2) Remove oil pump cover (Fig. 59). (3) Remove pump outer rotor and inner rotor with
shaft (Fig. 59).
(4) Wash all parts in a suitable solvent and inspect
carefully for damage or wear.
Fig.59OilPump
1 - INNER ROTOR AND SHAFT 2 - BODY 3 - DISTRIBUTOR DRIVESHAFT (REFERENCE) 4 - COTTER PIN 5 - RETAINER CAP 6 - SPRING 7 - RELIEF VALVE 8 - LARGE CHAMFERED EDGE 9 - BOLT 10 - COVER 11 - OUTER ROTOR
INSPECTION
Mating surface of the oil pump cover should be smooth. Replace pump assembly if cover is scratched or grooved.
Lay a straightedge across the pump cover surface (Fig. 60). If a 0.038 mm (0.0015 inch) feeler gauge can be inserted between cover and straightedge, pump assembly should be replaced.
Fig.60CheckingOilPumpCoverFlatness
1 - COVER 2 - STRAIGHT EDGE 3 - FEELER GAUGE
DR OIL PUMP (Continued)
Measure thickness and diameter of OUTER rotor. If outer rotor thickness measures 20.9 mm (0.825
inch) or less or if the diameter is 62.7 mm (2.469
inches) or less, replace outer rotor (Fig. 61).ENGINE - 5.9L
9 - 273
Fig.63MeasuringOuterRotorClearanceinHousing
1 - PUMP BODY 2 - OUTER ROTOR 3 - FEELER GAUGE
Fig.61MeasuringOuterRotorThickness
If inner rotor measures 20.9 mm (0.825 inch) or less, replace inner rotor and shaft assembly (Fig. 62).
Fig.62MeasuringInnerRotorThickness
Fig.64MeasuringClearanceBetweenRotors
1 - OUTER ROTOR 2 - FEELER GAUGE 3 - INNER ROTOR
Slide outer rotor into pump body. Press rotor to the side with your fingers and measure clearance between rotor and pump body (Fig. 63). If clearance is 0.356 mm (0.014 inch) or more, replace oil pump assembly.
Install inner rotor and shaft into pump body. If clearance between inner and outer rotors is 0.203
mm (0.008 inch) or more, replace shaft and both rotors (Fig. 64).Place a straightedge across the face of the pump, between bolt holes. If a feeler gauge of 0.102 mm (0.004 inch) or more can be inserted between rotors and the straightedge, replace pump assembly (Fig. 65).
Inspect oil pressure relief valve plunger for scoring and free operation in its bore. Small marks may be removed with 400-grit wet or dry sandpaper.
Fig.65MeasuringClearanceOverRotors
1 - STRAIGHT EDGE 2 - FEELER GAUGE
ENGINE - 5.9L
9 - 274
OIL PUMP (Continued)The relief valve spring has a free length of approx- imately 49.5 mm (1.95 inches). The spring should test between 19.5 and 20.5 pounds when compressed to 34 mm (1-11/32 inches). Replace spring that fails to meet these specifications (Fig. 66).
If oil pressure was low and pump is within specifi- cations, inspect for worn engine bearings or other reasons for oil pressure loss.
DR
INTAKE MANIFOLD DESCRIPTION
The aluminum intake manifold (Fig. 67) is a single plane design with equal length runners and uses a separate plenum, therefore the manifold does have a plenum gasket. It also uses separate flange gaskets and front and rear cross-over gaskets. Extreme care must be used when sealing the gaskets to ensure that excess sealant does not enter the intake runners causing a restriction. Whenever the intake manifold is removed inspect the plenum pan for evidence of excess oil buildup, this condition indicates that the plenum pan gasket is leaking.
Fig.66ProperInstallationofRetainerCap
1 - RETAINER CAP 2 - CHAMFER 3 - COTTER KEY
ASSEMBLY
(1) Install pump rotors and shaft, using new parts
as required.
(2) Position the oil pump cover onto the pump lbs.)
body. Tighten cover bolts to 11 N·m (95 in. torque.
(3) Install the relief valve and spring. Insert the
cotter pin.
(4) Tap on a new retainer cap. (5) Prime oil pump before installation by filling
rotor cavity with engine oil.
INSTALLATION
(1) Install oil pump. During installation slowly rotate pump body to ensure driveshaft-to-pump rotor shaft engagement.
(2) Hold the oil pump base flush against mating surface on No.5 main bearing cap. Finger tighten pump attaching bolts. Tighten attaching bolts to 41
N·m (30 ft. lbs.) torque.(3) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
Fig.67IntakeManifoldandThrottleBody—V-8Gas
EnginesTypical
1 - FUEL RAIL ASSEMBLY 2 - FUEL RAIL MOUNTING BOLTS 3 - FUEL RAIL CONNECTING HOSES
OPERATION
The intake manifold, meters and delivers air to the combustion chambers allowing the fuel delivered by the fuel injectors to ignite, thus producing power.
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.
DR INTAKE MANIFOLD (Continued)
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.
ENGINE - 5.9L
9 - 275
(1) Start the engine. (2) Spray a small stream of water at the suspected
(3) If a change in RPMs occur, the area of the sus-
pected leak has been found.
(4) Repair as required.
leak area.
REMOVAL
(1) Disconnect the negative cable from the battery. (2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(3) Remove the A/C compressor (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C COMPRESSOR - REMOVAL).
(4) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(5) Remove the accessory drive bracket. (6) Remove the air cleaner. (7) Perform the Fuel System Pressure release pro- cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV- ERY - STANDARD PROCEDURE). Disconnect the fuel lines (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STAN- DARD PROCEDURE).
(8) Disconnect the accelerator linkage (Refer to 14
- FUEL SYSTEM/FUEL INJECTION/THROTTLE CONTROL CABLE - REMOVAL) and if so equipped, the speed control and transmission kickdown cables.(9) Remove the return spring. (10) Remove the distributor cap and wires. (11) Disconnect the coil wires. (12) Disconnect the heat indicator sending unit
wire.
(13) Disconnect the heater hoses and bypass hose. (14) Remove the closed crankcase ventilation and
evaporation control systems.
(15) Remove intake manifold bolts. (16) Lift the intake manifold and throttle body out
of the engine compartment as an assembly.
(17) Remove and discard the flange side gaskets
and the front and rear end seals.
(18) Remove the throttle body bolts and lift the throttle body off the intake manifold (Fig. 68). Dis- card the gasket.
(19) If required, remove the plenum pan and gas-
ket. Discard gasket.
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Fig.68ThrottleBodyAssembly
1 - FUEL RAIL ASSEMBLY 2 - FUEL RAIL MOUNTING BOLTS 3 - FUEL RAIL CONNECTING HOSES
Clean cylinder block gasket surfaces using a suit-
able solvent.
all foreign material).
The plenum pan rail must be clean and dry (free of
INSPECTION
Inspect manifold for cracks. Inspect mating surfaces of manifold for flatness
with a straightedge.
INSTALLATION
(1) If removed, position new plenum gasket and
install plenum pan (Fig. 69).
(2) Tighten plenum pan mounting bolts as follows: † Step 1. Tighten bolts to 5.4 N·m (48 in. lbs.) † Step 2. Tighten bolts to 9.5 N·m (84 in. lbs.) † Step 3. Check all bolts are at 9.5 N·m (84 in.
lbs.)
(3) Install the flange gaskets. Ensure that the ver- tical port alignment tab is resting on the deck face of the block. Also the horizontal alignment tabs must be in position with the mating cylinder head gasket tabs (Fig. 71). The words MANIFOLD SIDE should be vis- ible on the center of each flange gasket.
(4) Apply Mopart GEN II Silicone Rubber Adhe- sive Sealant, or equivalent, to the four corner joints. An excessive amount of sealant is not required to ensure a leak proof seal. However, an excessive amount of sealant may reduce the effectiveness of the flange gasket. The sealant should be approxi- mately 5 mm (0.2 in) in diameter and 15 mm (0.6 in.) long.
ENGINE - 5.9L
9 - 276
INTAKE MANIFOLD (Continued)DR
Fig.69PlenumPanBoltTighteningSequence (5) Install the front and rear end seals (Fig. 70) Make sure the molded dowel pins on the end seals fully enter the corresponding holes in the cylinder block.
Fig.71IntakeManifoldFlangeGasketAlignment
1 - FLANGE GASKET 2 - ALIGNMENT TABS 3 - CYLINDER HEAD GASKET
follows (Fig. 72):
(8) Install the intake manifold bolts and tighten as † Step 1. Tighten bolts 1 through 4 to 8 N·m (72
in. lbs.) Tighten in alternating steps 1.4 N·m (12 in. lbs.) at a time † Step 2. Tighten bolts 5 through 12 to 8 N·m (72
† Step 3. Check all bolts are torqued to 8 N·m (72
† Step 4. Tighten all bolts in sequence to 16 N·m † Step 5. Check all bolts are torqued to 16 N·m(12 ft. lbs.)
in. lbs.)
in. lbs.)
(12 ft. lbs.)
(9) Install closed crankcase ventilation and evapo-
ration control systems.
(10) Connect the coil wires. (11) Connect the heat indicator sending unit wire. (12) Connect the heater hoses and bypass hose. (13) Install distributor cap and wires. (14) Hook up the return spring. (15) Connect the accelerator linkage (Refer to 14 - FUEL INJECTION/THROTTLE CONTROL CABLE - INSTALLATION) and if so
SYSTEM/FUEL
Fig.70FrontandRearEndSeals
1 - FRONT CROSS-OVER GASKET 2 - REAR CROSS-OVER GASKET
(6) Carefully lower intake manifold into position on the cylinder block and cylinder heads. After intake man- ifold is in place, inspect to make sure seals are in place. (7) Using a new gasket, install the throttle body onto the intake manifold. Tighten the bolts to 23 N·m (200 in. lbs.) torque.
DR INTAKE MANIFOLD (Continued)
ENGINE - 5.9L
9 - 277
Fig.72IntakeManifoldBoltTighteningSequence equipped, the speed control and transmission kick- down cables.
(16) Install the fuel lines (Refer to 14 - FUEL SYS- TEM/FUEL DELIVERY/QUICK CONNECT FIT- TING - STANDARD PROCEDURE).
(17) Install the accessory drive bracket and A/C compressor (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING/A/C INSTALLATION).
COMPRESSOR
(18) 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. (19) Install the air cleaner. (20) Fill cooling system (Refer to 7 - COOLING -STANDARD PROCEDURE).
(21) Connect the negative cable to the battery.
EXHAUST MANIFOLD DESCRIPTION
The exhaust manifolds (Fig. 73) are constructed of cast iron and are LOG type with balanced flow. One exhaust manifold is attached to each cylinder head.
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
(1) Disconnect the negative cable from the battery. (2) Raise and support the vehicle. (3) Remove the bolts and nuts attaching the
exhaust pipe to the engine exhaust manifold.
(4) Lower the vehicle. (5) Remove the exhaust heat shields.
Fig.73ExhaustManifolds—V-8GasEnginesTypical 1 - EXHAUST MANIFOLD (LEFT) 2 - BOLTS & WASHERS 3 - NUTS & WASHERS 4 - EXHAUST MANIFOLD (RIGHT) 5 - BOLTS & WASHERS
(6) Remove bolts, nuts and washers attaching
manifold to cylinder head.
(7) Remove manifold from the cylinder head.
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
CAUTION: If the studs came out with the nuts when removing the engine exhaust manifold, install new studs. Apply sealer on the coarse thread ends. Water leaks may develop at the studs if this precau- tion is not taken.
(1) Position the engine exhaust manifolds on the two studs located on the cylinder head. Install coni- cal washers and nuts on these studs (Fig. 74).
(2) Install two bolts and conical washers at the inner ends of the engine exhaust manifold outboard arms. Install two bolts WITHOUT washers on the center arm of engine exhaust manifold (Fig. 74). Starting at the center arm and working outward, tighten the bolts and nuts to 34 N·m (25 ft. lbs.) torque.
(3) Install the exhaust heat shields. (4) Raise and support the vehicle.
ENGINE - 5.9L
9 - 278
EXHAUST MANIFOLD (Continued)DR
(5) Assemble exhaust pipe to manifold and secure with bolts, nuts and retainers. Tighten the bolts and nuts to 34 N·m (25 ft. lbs.) torque.
(6) Lower the vehicle. (7) Connect the negative cable to the battery.
NOTE: Special Tool 6635 must be used to align the front cover and seal with the crankshaft.
(4) Position the special tool 6635 onto the crank-
shaft (Fig. 75).
Fig.74EngineExhaustManifoldInstallation-5.9L
Engines
1 - EXHAUST MANIFOLD (LEFT) 2 - BOLTS & WASHERS 3 - NUTS & WASHERS 4 - EXHAUST MANIFOLD (RIGHT) 5 - BOLTS & WASHERS
TIMING BELT / CHAIN COVER(S) REMOVAL
(1) Disconnect the negative cable from the battery. (2) Remove water pump (Refer to 7 - COOLING/
ENGINE/WATER PUMP - REMOVAL).
(3) Remove power steering pump (Refer to 19 -
STEERING/PUMP - REMOVAL). (4) Remove vibration damper
to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL).
(Refer
(5) Loosen oil pan bolts and remove the front bolt
at each side.
(6) Remove the cover bolts. (7) Remove chain case cover and gasket using
extreme caution to avoid damaging oil pan gasket.
INSTALLATION
(1) Be sure mating surfaces of chain case cover
and cylinder block are clean and free from burrs.
(2) The water pump mounting surface must be
cleaned.
(3) Using a new cover gasket, carefully install chain case cover to avoid damaging oil pan gasket. Use a small amount of Mopart Silicone Rubber Adhe- sive Sealant, or equivalent, at the joint between tim- ing chain cover gasket and the oil pan gasket. Finger tighten the timing chain cover bolts at this time.
Fig.75PositionSpecialTool6635ontoCrankshaft 1 - SPECIAL TOOL 6635
2 - OIL SEAL 3 - TIMING CHAIN COVER(5) Tighten chain case cover bolts to 41 N·m (30
ft.lbs.) torque. Tighten oil pan bolts to 24 N·m (215
in. lbs.) torque.(6) Remove special tool 6635. (7) Inspect the seal flange on the vibration damper. (8) Install vibration damper (Refer to 9 - ENGINE/ ENGINE BLOCK/VIBRATION DAMPER - INSTAL- LATION).
(9) Install water pump and housing assembly using new gaskets (Refer to 7 - COOLING/ENGINE/ WATER PUMP - INSTALLATION).
(10) Install power steering pump (Refer to 19 -
STEERING/PUMP - INSTALLATION).
(11) Install the serpentine belt (Refer to 7 - COOL- ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL- LATION).
(12) Install the cooling system fan (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLA- TION).
(13) Position the fan shroud and install the bolts.
Tighten the bolts to 11 N·m (95 in. lbs.) torque.
(14) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(15) Connect the negative cable to the battery. (16) Start engine check for leaks.
DR
ENGINE - 5.9L
9 - 279
TIMING BELT/CHAIN AND SPROCKETS REMOVAL
(1) Disconnect battery negative cable. (2) Remove Timing Chain Cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
(3) Re-install
the vibration damper bolt
finger tight. Using a suitable socket and breaker bar, rotate the crankshaft to align timing marks as shown in (Fig. 76).
(4) Remove camshaft sprocket attaching bolt and remove timing chain with crankshaft and camshaft sprockets.
Fig.77MeasuringTimingChainStretch
1 - TORQUE WRENCH 2 - 3.175 MM (0.125 IN.)
imaginary center line through both camshaft and crankshaft bores.
(2) Place timing chain around both sprockets. (3) Turn crankshaft and camshaft to line up with keyway location in crankshaft sprocket and in cam- shaft sprocket.
(4) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(5) Slide both sprockets evenly over their respec- tive shafts and use a straightedge to check alignment of timing marks (Fig. 78).
Fig.78AlignmentofTimingMarks
1 - TIMING MARKS
(6) Install the camshaft bolt. Tighten the bolt to 68
N·m (50 ft. lbs.) torque.
(7) Check camshaft end play. The end play should be 0.051-0.152 mm (0.002-0.006 inch) with a new thrust plate and up to 0.254 mm (0.010 inch) with a used thrust plate. If not within these limits install a new thrust plate.
(8) Install the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
Fig.76AlignmentofTimingMarks
1 - TIMING MARKS
INSPECTION—MEASURING TIMING CHAIN STRETCH
(1) Place a scale next to the timing chain so that
any movement of the chain may be measured.
(2) Place a torque wrench and socket over cam- shaft sprocket attaching bolt. Apply torque in the direction of crankshaft rotation to take up slack; 41
N·m (30 ft. lbs.) torque with cylinder head installed or 20 N·m (15 ft. lbs.) torque with cylinder head removed. With a torque applied to the camshaft sprocket bolt, crankshaft should not be permitted to move. It may be necessary to block the crankshaft to prevent rotation.(3) Hold a scale with dimensional reading even with the edge of a chain link. With cylinder heads installed, apply 14 N·m (30 ft. lbs.) torque in the reverse direction. With the cylinder heads removed, apply 20 N·m (15 ft. lbs.) torque in the reverse direc- tion. Note the amount of chain movement (Fig. 77). if its movement
(4) Install a new timing chain,
exceeds 3.175 mm (1/8 inch).
INSTALLATION
(1) Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact
9 - 280
ENGINE 5.9L DIESEL
ENGINE 5.9L DIESEL
TABLE OF CONTENTS
page
DR
page
ENGINE 5.9L DIESEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 282
DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING—ENGINE
INSPECTION INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . 304
INSTALLATION—CYLINDER HEAD COVER . 304
INSTALLATION—ROCKER HOUSING . . . . . 304DIAGNOSIS - MECHANICAL . . . . . . . . . . . . 283
INTAKE/EXHAUST VALVES & SEATS
DIAGNOSIS AND TESTING—SMOKE
DIAGNOSIS CHARTS . . . . . . . . . . . . . . . . . 285
DIAGNOSIS AND TESTING—CYLINDER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 305
STANDARD PROCEDURESTANDARD PROCEDURE - VALVES,
COMPRESSION/LEAKAGE TESTS . . . . . . . 288
GUIDES AND SPRINGS . . . . . . . . . . . . . . . . 305
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS . . . . . . . . 289
STANDARD PROCEDURE - REPAIR
STANDARD PROCEDURE - VALVE LASH
ADJUSTMENT AND VERIFICATION . . . . . . . 308
REMOVAL - VALVE SPRINGS AND SEALS . . . 308
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 309DAMAGED OR WORN THREADS . . . . . . . . 289
ROCKER ARM / ADJUSTER ASSY
STANDARD PROCEDURE—HYDROSTATIC
LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
REMOVAL
REMOVAL—ENGINE . . . . . . . . . . . . . . . . . . 290
REMOVAL—CRANKCASE BREATHER . . . . 291INSTALLATION
INSTALLATION—ENGINE . . . . . . . . . . . . . . 291
INSTALLATION—CRANKCASE BREATHER . 292SPECIFICATIONS
5.9L DIESEL . . . . . . . . . . . . . . . . . . . . . . . . 293
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . 294SPECIAL TOOLS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 310
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 311
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 312ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER
BLOCK REFACING . . . . . . . . . . . . . . . . . . . 312
STANDARD PROCEDURE - CYLINDER
BORE - DE-GLAZE . . . . . . . . . . . . . . . . . . . 313
STANDARD PROCEDURE—CYLINDER
5.9L DIESEL ENGINE
. . . . . . . . . . . . . . . . . 294
BORE REPAIR . . . . . . . . . . . . . . . . . . . . . . . 313
ENGINE DATA PLATE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 297
AIR CLEANER ELEMENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 298CYLINDER HEAD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 298
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
CLEANINGCLEANING—CYLINDER HEAD . . . . . . . . . . 300
CLEANING—CROSSHEADS . . . . . . . . . . . . 300
