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. . . . . . . . . . . . . . 301
CLEANING—PUSHRODSINSPECTION
INSPECTION - CYLINDER HEAD . . . . . . . . . 301
INSPECTION—CROSSHEADS . . . . . . . . . . 301
INSPECTION—PUSHRODS . . . . . . . . . . . . . 302
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 302CYLINDER HEAD COVER(S)
REMOVAL
REMOVAL—CYLINDER HEAD COVER . . . . 304
REMOVAL—ROCKER HOUSING . . . . . . . . . 304
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 304STANDARD PROCEDURE—CAM BORE
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
. . . . . . . . . . . . . . . . . . . . . . . . . 316INSPECTION
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVAL—CAMSHAFT BEARINGS . . . . . . 317
REMOVAL - CAMSHAFT . . . . . . . . . . . . . . . 317
. . . . . . . . . . . . . . . . . . . . . . . . . 318INSPECTION INSTALLATION
INSTALLATION - CAMSHAFT BEARINGS . . 320
INSTALLATION - CAMSHAFT . . . . . . . . . . . . 320CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING AND CRANKSHAFT JOURNAL CLEARANCE . . . . . . . . . . . . . . . . 321
CRANKSHAFT AND GEAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 322
REMOVAL—GEAR . . . . . . . . . . . . . . . . . . . . . 322
INSTALLATION - GEAR . . . . . . . . . . . . . . . . . . 322CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - MAIN BEARING
CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . 322
DR
ENGINE 5.9L DIESEL
9 - 281
CRANKSHAFT OIL SEAL - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 324CRANKSHAFT OIL SEAL - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 325CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 326SOLID LIFTERS/TAPPETS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 328
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 328PISTON & CONNECTING ROD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 329
STANDARD PROCEDURE - HEAD GASKETSELECTION . . . . . . . . . . . . . . . . . . . . . . . . . 330
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
CLEANING—PISTON AND CONNECTINGROD
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
INSPECTION
INSPECTION—PISTONS . . . . . . . . . . . . . . . 331
INSPECTION—CONNECTING ROD . . . . . . . 332
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 332PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 335
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 335FRONT MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 335REAR MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 337LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 337
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 337
DIAGNOSIS AND TESTING—ENGINE OILPRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 338
OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
STANDARD PROCEDURE - ENGINE OIL
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
OIL COOLER & LINES
CLEANING
CLEANING AND INSPECTION . . . . . . . . . . . 342
OIL FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 342OIL PAN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 342
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 342OIL PRESSURE RELIEF VALVE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 343
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 343OIL PRESSURE SENSOR/SWITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 343OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 344
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 344INTAKE MANIFOLD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 346
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 346EXHAUST MANIFOLD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 347
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 347VALVE TIMING
STANDARD PROCEDURE - TIMING
VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . 348
GEAR HOUSING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 349GEAR HOUSING COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 3509 - 282
ENGINE 5.9L DIESEL
ENGINE 5.9L DIESEL DESCRIPTION
DR
The cylinder block is constructed of cast iron. The casting is a skirted design which incorporates longi- tudal ribs for superior strength and noise reduction. The block incorporates metric straight thread o-ring fittings at lubrication oil access points. The engine (Fig. 1) is manufactured with the cylinders being a non-sleeved type cylinder. However, one approved service method is to bore out the cylinders and add cylinder sleeves to the cylinder block.
The cylinders are numbered front to rear (Fig. 2); 1
to 6. The firing order is 1–5–3–6–2–4.
Fig.2CylinderNumbering
Fig.1CumminsT 24-ValveTurbo-DieselEngine
DR ENGINE 5.9L DIESEL (Continued) DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING—ENGINE DIAGNOSIS - MECHANICAL
ENGINE 5.9L DIESEL
9 - 283
CONDITION
POSSIBLE CAUSES
CORRECTION
LUBRICATING OIL PRESSURE LOW
1. Low oil level.
1. (a) Check and fill with clean engine oil.
2. Oil viscosity thin, diluted or wrong specification.
3. Improperly operating pressure switch/gauge. 4. Relief valve stuck open. 6. If cooler was replaced, shipping plugs may have been left in cooler 7. Worn oil pump. 8. Suction tube loose or seal leaking. 9. Loose main bearing cap.
10. Worn bearings or wrong bearings installed.
11. Directed piston cooling nozzles under piston, bad fit into main carrier. 12. Loose oil rifle plug with saddle-jet style nozzles 13. Loose directed piston cooling nozzle. 14. Both J-jet and saddle jet style cooling nozzle installed.
LUBRICATING OIL PRESSURE TOO HIGH
1. Pressure switch/gauge not operating properly. 2. Engine running too cold.
3. Oil viscosity too thick.
4. Oil pressure relief valve stuck closed or binding
(b) Check for a severe external oil leak that could reduce the pressure. 2. (a) Verify the correct engine oil is being used. (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION). 2. (b) Look for reduced viscosity from fuel dilution. 3. Verify the pressure switch is functioning correctly. If not, replace switch/gauge. 4. Check/replace valve. 6. Check/remove shipping plugs.
7. Check and replace oil pump. 8. Check and replace seal. 9. Check and install new bearing. Tighten cap to proper torque. 10. Inspect and replace connecting rod or main bearings. Check and replace directed piston cooling nozzles. 11. Check directed piston cooling nozzles position.
12.Tighten oil rifle plug.
13. Tighten directed piston cooling nozzle.
14. Install correct style jet.
1. Verify pressure switch is functioning correctly. If not, replace switch/gauge. 2. Refer to Coolant Temperature Below Normal (Refer to 7 - COOLING - DIAGNOSIS AND TESTING). 3. Make sure the correct oil is being used. (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION). 4. Check and replace valve.
ENGINE 5.9L DIESEL
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ENGINE 5.9L DIESEL (Continued)DR
CONDITION
POSSIBLE CAUSES
CORRECTION
LUBRICATING OIL LOSS
1. External leaks.
2. Crankcase being overfilled.
3. Incorrect oil specification or viscosity.
COMPRESSION KNOCKS
EXCESSIVE VIBRATION
4. Oil cooler leak 5. High blow-by forcing oil out the breather. 6. Turbocharger leaking oil to the air intake. 1. Air in the fuel system.
2. Poor quality fuel or water/gasoline contaminated fuel.
3. Engine overloaded.
4. Improperly operating injectors.
1. Loose or broken engine mounts. 2. Damaged fan or improperly operating accessories. 3. Improperly operating vibration damper 4. Improperly operating electronically controlled viscous fan drive. 5. Worn or damaged generator bearing. 6. Flywheel housing misaligned. 7. Loose or broken power component.
8. Worn or unbalanced driveline components.
EXCESSIVE ENGINE NOISES
1. Drive belt squeal, insufficient tension or abnormally high loading.
2. Intake air or exhaust leaks.
1. Visually inspect for oil leaks. Repair as required. 2. Verify that the correct dipstick is being used. 3. (a) Make sure the correct oil is being used (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION). (b) Look for reduced viscosity from dilution with fuel. (c) Review/reduce oil change intervals. 4. Check and replace the oil cooler. 5. Check the breather tube area for signs of oil loss. Perform the required repairs. 6. Inspect the air ducts for evidence of oil transfer. Repair as required. 1. Identify location of air leak and repair. Do not bleed high pressure fuel system. 2. Verify by operating from a temporary tank with good fuel. Clean and flush the fuel tank. Replace fuel/water separator filter. 3. Verify the engine load rating is not being exceeded. 5. Check and replace misfiring/inoperative injectors.
1. Replace engine mounts. 2. Check and replace the vibrating components. 3. Inspect/replace vibration damper.
4. Inspect/replace fan drive.
5. Check/replace generator.
6. Check/correct flywheel alignment. 7. Inspect the crankshaft and rods for damage that causes an unbalance condition. Repair/replace as required. 8. Check/repair driveline components.
1. Check the automatic tensioner and inspect the drive belt. Make sure water pump, tensioner pulley, fan hub, generator and power steering pump turn freely. 2. Refer to Excessive Exhaust Smoke (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING).
DR ENGINE 5.9L DIESEL (Continued)
ENGINE 5.9L DIESEL
9 - 285
CONDITION
POSSIBLE CAUSES
CORRECTION
3. Excessive valve lash.
4. Turbocharger noise.
5. Gear train noise.
6. Power function knock.
3. Adjust valves. Make sure the push rods are not bent and rocker arms, adjusting screws, crossheads, are not severely worn. Replace bent or severely worn components. 4. Check turbocharger impeller and turbine wheel for housing contact. Repair/replace as required. 5. Visually inspect and measure gear backlash. Replace gears as required. 6. Check/replace rod and main bearings.
DIAGNOSIS AND TESTING—SMOKE DIAGNOSIS CHARTS
The following charts include possible causes and corrections for excess or abnormal exhaust smoke.
Small amounts of exhaust smoke (at certain times) are to be considered normal for a diesel powered engine.
POSSIBLE CAUSE
CORRECTION
EXCESSIVE BLACK SMOKE
Air filter dirty or plugged.
Air intake system restricted.
Air Leak in Intake System.
Diagnostic Trouble Codes (DTC’s) active or multiple,
intermittent DTC’s.
Engine Control Module (ECM) not calibrated or ECM has incorrect calibration. Exhaust system restriction is above specifications.
Fuel grade is not correct or fuel quality is poor.
Fuel injection pump malfunctioning.
Fuel injector malfunctioning.
Fuel return system restricted.
Intake manifold restricted.
Check Filter MinderT at air filter (Refer to 9 - ENGINE/ AIR INTAKE SYSTEM/AIR CLEANER ELEMENT - REMOVAL). Check entire air intake system including all hoses and tubes for restrictions, collapsed parts or damage. Repair/replace as necessary. Check entire air intake system including all hoses and tubes for cracks, loose clamps and/or holes in rubber ducts. Also check intake manifold for loose mounting hardware. Refer to Powertrain Diagnostic Procedures Information.
Refer to Powertrain Diagnostic Procedures Information.
Check exhaust pipes for damage/restrictions. Repair as necessary. Temporarily change fuel brands and note condition. Change brand if necessary. A DTC may have been set. If so, refer to Powertrain Diagnostic Procedures Information. A DTC may have been set. Perform 9Cylinder Cutout Test9 using DRB scan tool to isolate individual cylinders. Also refer to Powertrain Diagnostic Procedures Information and, to (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - DIAGNOSIS AND TESTING). Check fuel return lines for restriction (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - DIAGNOSIS AND TESTING). Remove restriction.
ENGINE 5.9L DIESEL
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ENGINE 5.9L DIESEL (Continued)DR
POSSIBLE CAUSE
CORRECTION
EXCESSIVE BLACK SMOKE
Manifold Air Pressure (Boost) Sensor or sensor circuit malfunctioning. Raw fuel in intake manifold.
Turbocharger air intake restriction. Turbocharger damaged.
Turbocharger has excess build up on compressor wheel and/or diffuser vanes. Turbocharger wheel clearance out of specification.
A DTC should have been set. Refer to Powertrain Diagnostic Procedures Information. Fuel injectors leaking on engine shutdown. Do Fuel Injector Test (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - DIAGNOSIS AND TESTING). Remove restriction. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM/TURBOCHARGER - INSPECTION). (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM/TURBOCHARGER - CLEANING). (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM/TURBOCHARGER - INSPECTION).
POSSIBLE CAUSE
CORRECTION
EXCESSIVE WHITE SMOKE
Air in fuel supply: Possible leak in fuel supply side (between transfer pump and fuel tank module). Coolant leaking into combustion chamber.
Diagnostic Trouble Codes (DTC’s) active or multiple, intermittent DTC’s. In very cold ambient temperatures, engine block heater is malfunctioning (if equipped). Engine coolant temperature sensor malfunctioning.
Engine Control Module (ECM) not calibrated or has incorrect calibration. Fuel filter plugged.
Fuel grade not correct or fuel quality is poor.
Fuel heater element or fuel heater temperature sensor malfunctioning. This will cause wax type build-up in fuel filter. Fuel injector malfunctioning.
Fuel injector hold-downs loose.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL TRANSFER PUMP - DIAGNOSIS AND TESTING). Do pressure test of cooling system (Refer to 7 - COOLING - DIAGNOSIS AND TESTING). Refer to Powertrain Diagnostic Procedures Information.
(Refer to 7 - COOLING/ENGINE/ENGINE BLOCK HEATER - REMOVAL). A DTC should have been set. Refer to Powertrain Diagnostic Procedures Information. Also check thermostat operation (Refer to 7 - COOLING/ENGINE/ ENGINE COOLANT THERMOSTAT - DIAGNOSIS AND TESTING). A DTC should have been set. Refer to Powertrain Diagnostic Procedures Information. Refer to Powertrain Diagnostic Manual for fuel system testing. Temporarily change fuel brands and note condition. Change brand if necessary. Refer to Fuel Heater Testing (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL HEATER - DIAGNOSIS AND TESTING). A DTC should have been set. Perform 9Cylinder cutout Test9 using DRB scan tool to isolate individual cylinders. Also refer to Powertrain Diagnostic Procedures Information and, (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - DIAGNOSIS AND TESTING). Torque to specifications.
DR ENGINE 5.9L DIESEL (Continued)
ENGINE 5.9L DIESEL
9 - 287
EXCESSIVE WHITE SMOKE
POSSIBLE CAUSE
Fuel injector protrusion not correct.
Fuel injection pump malfunctioning.
Fuel supply side restriction to transfer pump.
Fuel transfer (lift) pump malfunctioning.
Intake/Exhaust valve adjustments not correct (too tight).
Intake manifold air temperature sensor malfunctioning.
Intake manifold heater circuit not functioning correctly in cold weather.
Intake manifold heater elements not functioning correctly in cold weather.
Internal engine damage (scuffed cylinder).
Restriction in fuel supply side of fuel system.
CORRECTION
Check washer (shim) at bottom of fuel injector for correct thickness. (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - INSTALLATION) A DTC should have been set. Refer to Powertrain Diagnostic Procedures Information. Refer to Powertrain Diagnostic Manual for fuel system testing. A DTC may have been set. Refer to Powertrain Diagnostic Procedures Information. (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/ EXHAUST VALVES & SEATS - STANDARD PROCEDURE). A DTC should have been set. Refer to Powertrain Diagnostic Procedures Information. A DTC should have been set. Refer to Powertrain Diagnostic Procedures Information. Also check heater elements for correct operation. A DTC should have been set if heater elements are malfunctioning. Refer to Powertrain Diagnostic Procedures Information. Analyze engine oil and inspect oil filter to locate area of probable damage. Refer to Powertrain Diagnostic Manual for fuel system testing.
POSSIBLE CAUSE
CORRECTION
EXCESSIVE BLUE SMOKE
Dirty air cleaner or restricted turbocharger intake duct.
Air leak in boost system between turbocharger compressor outlet and intake manifold. Obstruction in exhaust manifold.
Restricted turbocharger drain tube.
Crankcase ventilation system plugged. Valve seals are worn, brittle, or improperly installed.
Valve stems and/or guides are worn.
Broken or Improperly installed piston rings.
Check Filter MinderT at air filter housing. (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER ELEMENT - REMOVAL). Service air charge system..
Remove exhaust manifold and inspect for blockage (Refer to 9 - ENGINE/MANIFOLDS/EXHAUST MANIFOLD - REMOVAL). Remove turbocharger drain tube and remove obstruction. Inspect crankcase ventilation system for function Replace valve stem oil seals (Refer to 9 - ENGINE/ CYLINDER HEAD/INTAKE/EXHAUST VALVES & SEATS - REMOVAL). Remove valves and inspect valves and guides. (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST VALVES & SEATS - STANDARD PROCEDURE). Tear down engine and inspect piston rings.
ENGINE 5.9L DIESEL
9 - 288
ENGINE 5.9L DIESEL (Continued)EXCESSIVE BLUE SMOKE
DR
POSSIBLE CAUSE
Excessive piston ring end gap.
Excessive cylinder bore wear and taper.
Cylinder damage.
Piston damage.
Turbocharger failure.
DIAGNOSIS AND TESTING—CYLINDER COMPRESSION/LEAKAGE TESTS
CYLINDER COMPRESSION PRESSURE
The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunc- tions.
Ensure batteries are completely charged and the engine starter motor is in good operating condition. Otherwise, the indicated compression pressures may not be valid for diagnostic purposes.
(1) Disconnect the fuel inlet line to the fuel trans-
fer pump. Plug the fuel line from the fuel tank.
(2) Start the engine and idle until the engine stalls
(runs out of fuel).
(3) Disconnect all three injector wire harness con-
nectors at the rocker housing.
(4) Remove the breather cover and cylinder head
cover.
(5) Remove the high pressure fuel line between the cylinder head and fuel rail for the cylinder to be tested.
(6) Remove the exhaust rocker lever. (7) Use Tool 9010 to remove the injector and cop-
per sealing washer.
43 N·m (32 ft. lbs.).
(8) Install the exhaust rocker lever and torque to
(9) Cover the remaining rocker levers with clean shop towels to prevent any oil splatter under the hood.
(10) Place a rag over the compression test tool fit- ting. Crank the engine for 2–3 seconds to purge any fuel that may have drained into the cylinder when the injector was removed.
CORRECTION
Remove pistons and measure piston ring end gap (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON RINGS - STANDARD PROCEDURE). Remove pistons and measure cylinder bore wear and taper (Refer to 9 - ENGINE/ENGINE BLOCK - STANDARD PROCEDURE). Remove pistons and inspect cylinder bore for cracks or porosity. Repair with cylinder liner if necessary. (Refer to 9 - ENGINE/ENGINE BLOCK - STANDARD PROCEDURE). Remove pistons and inspect for cracks, holes. Measure piston for out-of-round and taper (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON & CONNECTING ROD - INSPECTION). (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM/TURBOCHARGER - INSPECTION).
(11) Connect the compression test gauge. (12) Crank the engine for 5 seconds and record the pressure reading. Repeat this step three times and calculate the average of the three readings.
(13) Combustion pressure leakage can be checked if cylinder pressure is below the specification. Per- form the leakage test procedure on each cylinder according to the tester manufacturer instructions.
(14) Upon completion of the test check an erase
any engine related fault codes.
CYLINDER COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition. Combustion pressure leakage testing will detect: † Exhaust and intake valve leaks (improper seat- ing).† Leaks between adjacent cylinders or into water jacket.† Any causes for combustion/compression pressure loss (1) Start and operate the engine until it attains
normal operating temperature.
(2) Remove the breather cover and cylinder head
cover.
(3) Disconnect all three injector wire harness con-
nectors at the rocker housing.
(4) Bring the cylinder to be tested to TDC. (5) Remove the high pressure fuel line between the cylinder head and the fuel rail for the cylinder to be tested.
(6) Install capping Tool 9011 onto the rail. (7) Remove the high pressure connector nut and
high pressure connector with Tool 9015.
(8) Remove the exhaust and intake rocker lever.
DR ENGINE 5.9L DIESEL (Continued)
(9) Use Tool 9010 to remove the injector and cop-
per sealing washer.
injector bore.
(10) Install compression test Tool 9007 into the
(11) Connect the leakage tester and perform the leakage test procedure on each cylinder according to the tester manufacturer’s instructions.
(12) Upon completion of the test check and erase
any engine related fault codes.
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS
There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results. Do not use form-in- place gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket materials that are used in the engine area. Mopart Engine RTV GEN II, Mopart ATF-RTV, and Mopart Gasket Maker gasket materials, each have different properties and can not be used in place of the other.
MOPARt ENGINE RTV GEN II Mopart Engine RTV GEN II is used to seal com- ponents exposed to engine oil. This material is a spe- cially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.
MOPARt ATF RTV Mopart ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and seal- ing properties to seal components exposed to auto- matic coolants, and moisture. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.
transmission fluid,
engine
MOPARt GASKET MAKER Mopart Gasket Maker is an anaerobic type gasket material. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic
ENGINE 5.9L DIESEL
9 - 289
material is for use between two machined surfaces. Do not use on flexible metal flanges.
MOPARt GASKET SEALANT Mopart Gasket Sealant is a slow drying, perma- nently soft sealer. This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts under all temperatures. This mate- rial is used on engines with multi-layer steel (MLS) cylinder head gaskets. This material also will pre- vent corrosion. Mopart Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER APPLICATION
Assembling parts using a form-in-place gasket requires care but it’s easier than using precut gas- kets.
Mopart Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant to one gasket surface. Be certain the material sur- rounds each mounting hole. Excess material can eas- ily be wiped off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during assembly to prevent smear- ing material off the location.
Mopart Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 3 mm (0.120 in.) in diameter. All mounting holes must be circled. For corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towel. Components should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to prevent smearing material off the location.
Mopart Gasket Sealant in an aerosol can should be applied using a thin, even coat sprayed completely over both surfaces to be joined, and both sides of a gasket. Then proceed with assembly. Material in a can w/applicator can be brushed on evenly over the sealing surfaces. Material in an aerosol can should be used on engines with multi-layer steel gaskets.
STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain the original center line.
tially, this repair consists of:
Damaged or worn threads can be repaired. Essen- † Drilling out worn or damaged threads. † Tapping the hole with a special Heli-Coil Tap, or
equivalent.
ENGINE 5.9L DIESEL
9 - 290
ENGINE 5.9L DIESEL (Continued) † Installing an insert into the tapped hole to bring the hole back to its original thread size.STANDARD PROCEDURE—HYDROSTATIC LOCK
CAUTION: DO NOT use the starter motor to rotate the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock (regardless of what caused the problem), follow the steps below.
(1) Disconnect the negative cable(s) from the bat-
oil.
tery.
(2) Inspect air
induction system, and intake manifold to ensure system is dry and clear of foreign material.
cleaner,
(3) Place a shop towel around the fuel injectors to catch any fluid that may possibly be under pressure in the cylinder head. Remove the fuel injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - REMOVAL).
(4) With all injectors removed, rotate the crank- shaft using the crankshaft barring tool (PN 7471–B). (5) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
cylinders.
(6) Be sure all fluid has been removed from the
extension pipe.
(7) Repair engine or components as necessary to
connectors.
prevent this problem from occurring again.
(8) Squirt a small amount of engine oil into the cylinders to lubricate the walls. This will prevent damage on restart.
(9) Install fuel injectors (Refer to 14 - FUEL SYS-
INJECTION/FUEL
INJECTOR
TEM/FUEL INSTALLATION).
(10) Drain engine oil. Remove and discard the oil filter (Refer to 9 - ENGINE/LUBRICATION/OIL FIL- TER - REMOVAL).
(11) Install the drain plug. Tighten the plug to 50
N·m (37 ft. lbs.) torque.
(12) Install a new oil filter (Refer to 9 - ENGINE/
LUBRICATION/OIL FILTER - INSTALLATION).
(13) Fill engine crankcase with the specified amount and grade of oil (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES SPECIFICA- TIONS).
(14) Connect the negative cable(s) to the battery. (15) Start the engine and check for any leaks.
REMOVAL
REMOVAL—ENGINE
(1) Disconnect both battery negative cables. (2) Disconnect engine grid heater harness at grid
heater relays.
DR
(3) Disconnect electrical connections from rear of
alternator.
(4) Recover A/C refrigerant. (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING - STAN- DARD PROCEDURE).
(5) Raise vehicle on a hoist. (6) Drain engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(7) Remove engine oil drain plug and drain engine
(8) Remove fan/drive assembly. Refer to Section 7
– Fan/Drive Removal
(9) Remove radiator upper hose. (10) Remove upper fan shroud mounting bolts. (11) Disconnect the coolant recovery bottle hose
from the radiator fill neck and remove bottle.
(12) Using a 36mm wrench, remove viscous fan/ drive assembly. (Refer to 7 - COOLING/ENGINE/RA- DIATOR FAN - REMOVAL).
(13) Remove cooling fan and shroud together. (14) Disconnect heater core supply and return hoses from the cylinder head fitting and coolant pipe.
(15) Raise vehicle on a hoist. (16) Remove transmission and transfer case (if
equipped).
(17) Disconnect exhaust pipe from turbocharger
(18) Disconnect engine harness to vehicle harness
(19) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).
(20) Remove flywheel/flexplate. (21) Remove transmission adapter (22) Disconnect A/C suction/discharge hose from
the rear of the A/C compressor.
(23) Lower vehicle. (24) Disconnect lower radiator hose from radiator
outlet.
(25) Automatic transmission models: (26) Disconnect transmission oil cooler lines from
in front of radiator using special tool #6931
(27) Remove radiator. (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(28) If A/C equipped, disconnect A/C condenser
refrigerant lines.
(29) Disconnect charge air cooler piping. (30) Remove charge air cooler mounting bolts. (31) Remove charge air cooler (and A/C condenser
if equipped) from vehicle.
(32) Remove damper and speed indicator ring from
front of engine.
(33) Disconnect engine block heater connector. (34) Disconnect A/C compressor and pressure sen-
sor electrical connectors.
DR ENGINE 5.9L DIESEL (Continued)
ENGINE 5.9L DIESEL
9 - 291
(51) Loosen but do not remove engine mount
through bolts and nuts.
(52) Disconnect hood support struts and position
hood out of the way.
lift brackets.
out of the mounts.
chassis.
(53) Attach a chain with two hooks to the engine
(54) While keeping engine level, lift straight up
(55) Rotate nose of engine upward and pull out of
REMOVAL—CRANKCASE BREATHER
(1) Remove the oil fill cap. (2) Remove the breather cover bolts (Fig. 4). (3) Remove breather cover. (4) Disconnect breather tube and lube oil drain
tube from breather.
(5) Remove breather mounting bolts. (6) Remove breather from cylinder head cover.
(35) Remove the passenger battery ground cable from the engine block. Remove the driver side bat- tery ground cable from the engine block.
(36) Remove power steering pump from engine by
removing 3 bolts.
(37) Remove accelerator linkage cover. (38) Disconnect cables from APPS if early model build (39) If late model build, (40) Disconnect the ECM power connector. (41) Disconnect the ECM ground wire from the
hydroform screw.
(42) Disconnect the fuel supply and return hoses. (43) Remove the cylinder head cover. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(44) Disconnect the 3 injector harness connectors at the rocker housing. Disconnect the wire harnesses from the injectors.
(45) Remove the rear engine lift bracket. (46) Remove cylinder #4, #5, and #6 intake and exhaust rocker arms, pedestals, and push tubes. Note the original location for re-assembly.
line shield bolts and rotate
(47) Loosen #6 fuel shield out of the way.
(48) Remove cylinder #5 and #6 high pressure fuel lines. Remove the fuel connector tube nut and fuel con- nector tube. 46. Remove cylinder #5 and #6 fuel injector.
(49) Remove rocker housing. (50) Remove two cylinder head bolts in location 4
and 12 according to the diagram below and install Tool # 9009 (Fig. 3).Fig.4CrankcaseBreatherVaporCanister
1 - BREATHER COVER BOLT 2 - BREATHER COVER 3 - BREATHER TUBE 4 - ROCKER COVER 5 - BREATHER TUBE MOUNTING BRACKET 6 - LUBE OIL DRAIN TUBE 7 - O-RING 8 - BREATHER 9- BREATHER MOUNTING BOLT
INSTALLATION
INSTALLATION—ENGINE
(1) Remove cylinder head bolts in locations 4 and 12 according to the diagram below. Install special Tool 9009.
Fig.3ENGINELIFTBRACKET
1 - Head bolt 2 - Engine Lift Bracket 3 - Head Bolt
ENGINE 5.9L DIESEL
9 - 292
ENGINE 5.9L DIESEL (Continued)DR
(2) Lower engine into the engine compartment and install the engine the engine mount through bolts and nuts.
(3) Tighten the mount through bolts and nuts to
88 N-m (65 ft-lbs) torque.
(4) Remove the engine lifting device (Tool 9009). (5) Check cylinder head capscrew length and
install into cylinder head.
(6) Torque alternately to 70 N-m (52 ft-lbs). Torque alternately to 105 N-m (77 ft-lbs). Rotate 90 degrees. (7) Install rocker housing. Torque to 24 N-m (18 ft- lbs). Refer to Section 9 Rocker Housing Installation (8) Replace injector o-ring and sealing washer on injectors #5 and #6. Install injectors and alternately tighten hold-down capscrews to 10 N-m (89 in-lbs).
(9) Install fuel connector tube and fuel connector
tube nut. Torque to 50 N-m (37 ft-lb). 10.
(10) Install #5 and #6 high pressure fuel lines. Fol- low correct torque sequence per section 14. Torque fuel line fittings to 30 N-m (22 ft-lb). Torque brace capscrew to 24 N-m (18 ft-lb).
(11) Install rear engine lift bracket. Torque to 77
N-m (57 ft-lb).
(12) Install push tubes, rocker arms, and pedestals for cylinders #4, #5, and #6. Torque the mounting bolts to 36 N-m (27 ft-lbs).
(13) Reset valve lash on cylinders #4, #5, and #6.
Torque adjusting nuts to 24 N-m (18 ft-lbs).
(14) Install cylinder head cover. Torque to 24 N-m (18 ft-lbs).(Refer to 9 - ENGINE/CYLINDER HEAD - INSTALLATION).
(15) Connect breather tube and lube oil drain tube to breather housing. Install breather housing. Torque capscrews to 24 N-m (18 ft-lbs)
(16) Connect fuel supply and return hoses. (17) Connect ECM ground to hydroform screw.
Connect ECM power connector.
the throttle linkage cover.
(19) Install the power steering pump. (20) Install the damper and speed indicator ring.
Torque to 40 N-m (30 ft-lb) plus 60 degrees.
(21) Connect the engine block heater connection. (22) Connect the A/C compressor and pressure sen-
sor connectors
(23) Install the charge air cooler and a/c condenser (if equipped). Install and tighten the charge air cooler mounting bolts to 2 N-m (17 in-lbs).
(24) Connect the charge air cooler piping. Torque
all clamps to 8 N-m (72 in-lbs).
(25) Connect the a/c refrigerant lines to the a/c
condenser (if equipped).
(26) Install the radiator upper support panel. (27) Install radiator. (28) Connect the transmission quick-connect oil
cooler lines.
(29) Raise vehicle. (30) Connect a/c compressor suction/discharge hose
(if equipped).
(31) Install the radiator lower hose and clamps. (32) Install
the battery negative cables to the
engine block on the driver and passenger side.
(33) Install the transmission adapter with a new camshaft rectangular ring seal. Torque to 77 N-m (57
ft-lb).(34) Install the flywheel/flexplate. Torque to 137
N-m (101 ft-lb).
(35) Install the starter motor. Torque to 43 N-m (32 ft-lb). (Refer to 8 - ELECTRICAL/STARTING/ STARTER MOTOR - INSTALLATION).
(36) Connect engine to vehicle harness connectors. (37) Install transmission and transfer case (if
equipped).
elbow.
(38) Connect the exhaust pipe to the turbocharger
(39) Connect the transmission auxiliary oil cooler
lines (if equipped).
(40) Lower the vehicle. (41) Connect the heater core supply and return hoses. (42) Install the cooling fan and upper fan shroud at the same time. (Refer to 7 - COOLING/ENGINE/ RADIATOR FAN - INSTALLATION).
(43) Install the coolant recovery bottle. (44) Install the windshield washer bottle. (45) Install the upper radiator hose and clamps. (46) Raise vehicle. (47) Connect electronically controlled fan drive
wire harness. Install lower radiator fan shroud.
(48) Change oil filter and install new engine oil. (49) Fill the cooling system with coolant. (Refer to
7 - COOLING - STANDARD PROCEDURE).
(50) Connect grid heater harness at grid heater
relays.
nator.
(52) Start the engine and inspect for engine oil,
coolant, and fuel leaks.
INSTALLATION—CRANKCASE BREATHER
(1) Install a new o-ring onto the breather element. (2) Lubricate o-ring and install into cylinder head
cover. Torque capscrews to 10 N·m (89 in. lbs.).
(3) Connect breather tube and lube oil drain tube. (4) Install breather cover (Fig. 4). Torque to 24
N·m (18 ft. lbs.)
(5) Install oil fill cap.
(18) Install the APPS cable(s) to the APPS. Install
(51) Connect electrical connections to rear of alter-
DR ENGINE 5.9L DIESEL (Continued) SPECIFICATIONS
5.9L DIESEL
DESCRIPTION
Engine Type
Bore and Stroke
Displacement
Compression Ratio
305/250/235 H.P. Version Horsepower (A/T and 5
Speed M/T)
SPECIFICATION
In-Line 6 Cyl. Turbo
Diesel
102.0 X 120.0 mm (4.02 X 4.72 in.) 5.9L (359 cu. in.)
17.2:1
235 @ 2700 rpm
(CARB)
250 @2900 rpm (49
State)
Horsepower (6 Speed M/T
305 @ 2900 rpm
Only)
Torque Rating (A/T and 5
460 ft. lbs. @ 1400 rpm
Speed M/T)
Torque Rating (6 Speed
555 ft. lbs. @ 1400 rpm
M/T Only) Firing Order
1-5-3-6-2-4
ENGINE 5.9L DIESEL
9 - 293
DESCRIPTION
Piston Pins
SPECIFICATION
Pin Diameter (Min.)
39.990 mm (1.5744
inch)
(Max)
40.003 mm (1.5749 in.)
Bore Diameter (Min)
40.006 mm (1.5750
inch.
(Max)
40.012 mm (1.5753 in.)
Piston Ring End Gap
Top Ring
Intermediate
Oil Control
Connecting Rods
0.26 – 0.36 mm
(0.010 – 0.014 in.)
0.85 – 1.15 mm (0.33 – 0.045 in.) 0.25 – 0.55 mm
(0.010 – 0.021 in.)
Pin Bore Diameter (Max.
w/busing installed)
40.019 mm – 40.042
mm (1.5764 – 1.5765Side Clearance
in.)
0.100 – 0.330 mm (0.004 – 0.013 in.)
Lubrication System
Pressure Feed-Full Flow
CYLINDER HEAD
Cylinder Block
Crankshaft
Cylinder Head
Combustion Chambers
Camshaft Pistons
With Bypass Valve
Cast Iron
Induction Hardened
Forged Steel
Cast Iron With Valve
Seat Inserts
High Swirl Bowl
Chilled Ductile Iron
Cast Aluminum
Overall Flatness End to
0.305 mm (0.012 in.)
End (Max.)
Overall Flatness Side to
0.076 mm (0.003 in.)
Side (Max.)
Intake Valve Seat Angle Exhaust Valve Seat Angle
Valve Stem Diameter
(Min) (Max)
30° 45°
6.96 mm (0.2740 in.) 7.01 mm (0.2760 in.) 0.79 mm (0.031 in.)
Connecting Rods
Cross Rolled Micro Alloy
PISTONS AND CONNECTING RODS
Valve Rim Thickness
(Min.)
Piston
Skirt Diameter
101.864 – 101.887 mm
Ring Groove Clearance
Intermediate (Min.)
(Max)
Oil Control (Min)
(Max)
(4.010 – 4.011 in.)
0.045 mm (.0018 inch) 0.095 mm (0.0037 inch) 0.040 mm (.0016 inch) 0.085 mm (0.0033 inch)
OIL PRESSURE
At Idle
At 2,500 rpm
Regulating Valve Opening
Pressure
69 kPa (10 psi) 207 kPa (30 psi) 517 kPa (75 psi)
Oil Filter Bypass Pressure
344.75 kPa (50 psi)
Setting
ENGINE 5.9L DIESEL
9 - 294
ENGINE 5.9L DIESEL (Continued) TORQUETORQUE CHART 5.9L DIESEL ENGINE
DR
SPECIAL TOOLS
5.9L DIESEL ENGINE
DESCRIPTION
N·m
In. Lbs.
Ft. Lbs.
Connecting Rod—Bolts
Step 1
Step 2
Step 3— —
30
22
60
44
Rotate 60 degreesCrankshaft Main Cap—Bolts
50
80Step 1
Step 2
Step 3Rotate 90°
37
59Cylinder Head—Bolts
UniversalDriverHandle-C4171
—
70
52
Step 1
Step 2 Back off 360 degrees Step 3
Step 4 Verify Step 577
105
105
77
Rotate All Bolts 1/4— —
Cylinder Head Cover Bolts Breather Cover Bolts HPC Nut Fuel Delivery Lines—Banjo Fuel Drain Line—Banjo Fuel line—rail to cylinder head Fuel line—pump to fuel rail Injector fuel line brace Fuel rail holddown bolt Oil Pan—Bolts Oil Pan—Drain Plug Oil Pressure Regulator—Plug Oil Pressure Switch
Oil Pump—Bolts Step1
Step2Oil Suction Tube (Flange)— Bolts Oil Suction Tube (Brace)— Bolt Rocker Arm/Pedestal—Bolts
24
24
50
24
2430
30
24
24
28
50
80
1824
24
43
36
Turn — —
— —
—
— —
— — — —
— —
—
—
—
18
18
37
18
1822
22
18
18
21
37
60
1318
18
32
27
CrankshaftBarringTool-7471-B
CrankshaftFrontOilSealInstaller-8281
ValveSpringCompressor-8319A
TestPlug-8442
DR ENGINE 5.9L DIESEL (Continued)
ENGINE 5.9L DIESEL
9 - 295
Adapter-8462
CompressionTestAdapter-9007
EngineSupportFixture-8534
EngineLiftBracket-9009
TAPPETINSTALLATIONTOOL-8502
FuelInjectorRemover-9010
STEELBRACKET-8534-A
ENGINE 5.9L DIESEL
9 - 296
ENGINE 5.9L DIESEL (Continued)DR
FUELBLOCKOFFPLUG-9011
FuelInjectorTube(Connector)Remover-9015
FUELTESTFITTING-9013
TURBOTESTADAPTER-9022
DR
ENGINE 5.9L DIESEL
9 - 297
has experienced. A drop in air pressure due to an air cleaner element restriction moves diaphragm and yellow disc will indicate size of air drop.
CAUTION: Certain engine degreasers or cleaners may discolor or damage plastic housing of Filter Minder. Cover and tape Filter Minder if any engine degreasers or cleaners are to be used.
To test, turn engine off. If yellow disc (Fig. 7) has reached red colored zone on graduated scale, air cleaner element should be replaced. Refer to Removal / Instal- lation.
Resetting Filter Minder: After air cleaner (filter) element has been replaced, press rubber button on top of Filter Minder (Fig. 7). This will allow yellow colored disc to reset. After button has been pressed, yellow disc should spring back to UP position.
If Filter Minder gauge has reached red colored zone, and after an examination of air cleaner (filter) element, element appears to be clean, high reading may be due to a temporary condition such as snow build-up at air intake. Temporary high restrictions may also occur if air cleaner (filter) element has got- ten wet such as during a heavy rain or snow. If this occurs, allow element to dry out during normal engine operation. Reset rubber button on top of Filter Minder and retest after element has dried.
ENGINE DATA PLATE DESCRIPTION
The engine data plate contains specific information that is helpful to servicing and obtaining parts for the engine. The data plate can be found in two places. Some models have a data plate is located on the left side of the engine, affixed to the APPS bracket. Some models will have the data plate affixed to the breather cover on the left side of the engine. Information that can be found on the data plate includes: † Date of Engine Manufacture † Engine Serial Number † Control Parts List (CPL) † Engine Rated Horsepower † Engine Firing Order † Engine Displacement † Valve Lash Reset Specifications If the engine data plate is missing or not legible, the engine serial number is used for engine identifi- cation. The engine serial number is stamped on the right side of the block, on top of the oil cooler cavity (Fig. 5).
Fig.5EngineSerialNumberLocation
AIR CLEANER ELEMENT REMOVAL
Testing Air Cleaner Element using Filter Minder™
Do not attempt to unnecessarily remove top of air cleaner housing for air cleaner element inspection on diesel engines.
The air cleaner (filter) housing is equipped with an air Filter Minder™ gauge (Fig. 6). This air flow restriction gauge will determine when air cleaner ele- ment is restricted and should be replaced.
The Filter Minder™ consists of a diaphragm and calibrated spring sealed inside of a plastic housing (Fig. 7). A yellow colored disc attached to diaphragm moves along a graduated scale on side of Filter Minder. After engine has been shut off, a ratcheting device located within Filter Minder will hold yellow disc at highest restriction that air cleaner element
Fig.65.9LDIESELAIRCLEANER-FILTER
MINDER™
1 - CLIPS 2 - FILTER COVER 3 - FILTER MINDER™ 4 - INLET AIR TEMPERATURE/ PRESSURE SENSOR 5 - FILTER HOUSING
ENGINE 5.9L DIESEL
9 - 298
AIR CLEANER ELEMENT (Continued)REMOVAL
DR
(1) Disconnect battery negative cables. (2) Raise vehicle on hoist. (3) Drain engine coolant. (4) Disconnect exhaust pipe from turbocharger
(5) Lower vehicle. (6) Disconnect air inlet temperature/pressure sen-
elbow.
sor.
(7) Remove air cleaner housing and snorkel from the vehicle. Cap off turbocharger air inlet to prevent intrusion of dirt or foreign material.
(8) Disconnect cab heater core supply and return
hoses from the cylinder head and heater pipe.
(9) Disconnect turbocharger oil drain tube at rub- ber hose connection. Cap off open ports to prevent intrusion of dirt or foreign material.
(10) Disconnect turbocharger oil supply line at the turbocharger end. Cap off open ports to prevent intrusion of dirt or foreign material.
(11) Remove exhaust manifold-to-cylinder head bolts, spacers, heat shield, retention straps, and cab heater plumbing. Remove exhaust manifold and tur- bocharger from the vehicle as an assembly.
(12) Remove cooling fan assembly. (13) Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(14) Remove cooling fan support
from cylinder
block.
(15) Remove upper generator bolt,
loosen lower generator bolt, and rotate generator away from cylin- der head.
(16) Disconnect radiator upper hose from the ther-
mostat housing.
(17) Disconnect the Intake Air Temperature, Man- ifold Air Pressure, and Coolant Temperature sensor connector.
(18) Remove the engine harness to cylinder head
attaching bolts and P-clips at front of head.
(19) Remove the throttle linkage cover (Fig. 8). (20) Remove the six (6) accelerator pedal position sensor assembly-to-cylinder head bracket bolts (Fig. 9) and secure the entire assembly out of the way. Disconnect the APPS connector (Fig. 10). It is not necessary to disconnect the cables from the throttle control assembly.
(21) Remove the intake air grid heater wires from
the grid heater.
(22) Remove engine oil level indicator tube attach- ing bolt at fuel filter housing bracket and inlet air connection..
(23) Remove the charge air cooler-to-air inlet hous-
ing pipe.
Fig.7FILTERMINDER™-5.9LDIESEL
1 - PRESS BUTTON TO RESET 2 - YELLOW DISC 3 - RED ZONE 4 - TO AIR FILTER HOUSING 5 - FILTER MINDER
Filter Removal
(1) The housing cover is equipped with spring clips (Fig. 6) and is hinged with plastic tabs. Unlatch clips from top of air cleaner housing and tilt housing cover up for cover removal.
(2) Remove air cleaner element from air cleaner
housing.
INSTALLATION
(1) Before installing new air cleaner element (fil-
ter), clean inside of air cleaner housing.
(2) Position air cleaner cover to tabs on front of air cleaner housing. Latch spring clips to seal cover to housing.
CYLINDER HEAD DESCRIPTION
The cylinder head is constructed of cast iron and is a one piece cross flow design with four valves per cyl- inder. The arrangement of two intake and two exhaust valves per cylinder allows for a centrally located injector. The cylinder head also includes an integral thermostat housing, and a longitudal fuel return rifle, which exits at the rear of the head. The 24 valve design also includes integrally cast valve guides and hard- ened intake and exhaust valve seat inserts.
intake manifold, an integral
DR CYLINDER HEAD (Continued)
ENGINE 5.9L DIESEL
9 - 299
Fig.8ThrottleLinkageCover
Fig.10APPSConnector
1 - CABLE/LEVER/LINKAGE COVER 2 - PUSH UP LOWER TAB 3 - SCREWS/CLIPS (2) 4 - TAB PUSH HERE
1 - APPS 2 - TAB 3 - PUSH FOR REMOVAL 4 - APPS CONNECTOR
(27) Remove the engine lift bracket from the rear
of the cylinder head.
(28) Remove the high pressure pump to fuel
rail fuel line as follows:
(a) Loosen fuel line nuts at fuel pump and at
fuel rail.
(b) Use a back-up wrench on the fitting at the
fuel pump to keep it from loosening. (29) Remove the fuel rail to cylinder head fuel
lines as follows:
(a) Loosen No. 6 high pressure fuel line shield
and position out of way.
(b) Loosen the fuel line nuts at the fuel rail and
at the cylinder head.
(c) Remove the fuel intake manifold cover. (30) Remove the fuel rail as follows:
line bracket bolts at the
(a) Remove fuel rail pressure sensor connector. (b) Remove banjo fitting at pressure limiting
valve.
(c) Remove fuel rail bolts and fuel rail.
(31) Remove the low pressure lines as follows:
(a) Remove the fuel drain banjo fitting on the
front side of fuel filter housing.
(b) Remove the fuel drain banjo fitting on rear
side of fuel filter housing.
(c) Remove the fuel drain line support bracket
on rear side of filter housing. (d) Remove fuel drain hose.
Fig.9APPSAssembly
1 - LEVER 2 - MOUNTING BOLTS (6) 3 - WIRE HARNESS CLIP 4 - CALIBRATION SCREWS (NO ADJUSTMENT) 5 - APPS ASSEMBLY
(24) Remove the engine wire harness attaching bolt and wire harness push-in fastener from air inlet housing.
(25) Remove the air inlet housing and intake grid
heater from the intake manifold cover.
(26) Remove the two grid heater harness-to-cylin-
der head attaching bolts at front of cylinder head.
ENGINE 5.9L DIESEL
9 - 300
CYLINDER HEAD (Continued)DR
(e) Remove banjo fitting at bottom of fuel filter
housing.
(f) Disconnect fuel supply hose at lift pump.
(32) Disconnect fuel heater, water in fuel sensor,
and fuel lift pump connectors.
(33) Remove the fuel
filter assembly-to-cylinder head bolts and remove filter assembly from vehicle. (34) Remove wire harness P-clip from cylinder
head (located behind filter housing).
(35) Remove the cylinder head cover(Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(36) Disconnect rocker housing injector harness
connectors.
(37) Remove injector harness nuts from injectors. (38) Remove the rocker levers (Fig. 11), cross heads and push rods (Fig. 12). Mark each component so they can be installed in their original positions.
NOTE: The #5 cylinder exhaust and the #6 cylinder intake and exhaust push rods are removed by lift- ing them up and through the provided cowl panel access holes. Remove the rubber plugs to expose these relief holes.
Fig.11RockerArmandPedestalRemoval
1 - ROCKER ARM 2 - PEDESTAL
(39) Remove the fuel return line and banjo bolt at the rear of the cylinder head. Be careful not to drop the two (2) sealing washers.
(40) Remove the fuel injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - REMOVAL).
Fig.12PushRodRemoval
(41) Remove rocker housing bolts and rocker hous-
ing and gasket.
(42) Reinstall the engine lift bracket at the rear of
cylinder head. Torque to 77 N·m (57 ft. lbs.).
(43) Remove twenty six (26) cylinder head-to-block
(44) Attach an engine lift crane to engine lift brackets and lift cylinder head off engine and out of vehicle.
(45) Remove the head gasket and inspect for fail-
bolts.
ure.
CLEANING
CLEANING—CYLINDER HEAD
CAUTION: Do not wire brush head surface while fuel injectors are still installed. Fuel injector dam- age can result.
Remove fuel injector before cleaning (if not already
removed during cylinder head removal).
Clean the carbon from the injector nozzle seat with
a nylon or brass brush.
Scrape the gasket residue from all gasket surfaces. Wash the cylinder head in hot soapy water solution
(88°C or 140°F).
der head.
After rinsing, use compressed air to dry the cylin-
Polish the gasket surface with 400 grit paper. Use an orbital sander or sanding block to maintain a flat surface.
CLEANING—CROSSHEADS
Clean all crossheads in a suitable solvent. If neces- sary, use a wire brush or wheel to remove stubborn deposits. Rinse in hot water and blow dry with com- pressed air.
DR CYLINDER HEAD (Continued) CLEANING—PUSHRODS
Clean the pushrods in a suitable solvent. Rinse in hot water and blow dry with compressed air. If nec- essary, use a wire brush or wheel to remove stubborn deposits.
INSPECTION
INSPECTION - CYLINDER HEAD
Inspect the cylinder head for cracks in the combus- tion surface. Pressure test any cylinder head that is visibly cracked. A cylinder head that is cracked between the injector bore and valve seat can be pres- sure tested and reused if OK; however, if the crack extends into the valve seat insert bore, the cylinder head must be replaced.
Visually inspect the cylinder block and head com- bustion surfaces for localized dips or imperfections. Check the cylinder head and block combustion sur- faces for overall out-of-flatness. If either the visual or manual inspection exceeds the limits, then the head or block must be surfaced.
Check the top surface for damage caused by the
cylinder head gasket leaking between cylinders.
Inspect the block and head surface for nicks, ero-
sion, etc.
Check the head distortion. Maximum overall vari- ation end to end is 0.305 mm (0.012 inch) (Fig. 13), and maximum overall variation side to side 0.076
mm ( .003 in.).DO NOT proceed with the in-chassis overhaul if the cylinder head or block surface is damaged or not flat (within specifications).
Check block surface for distortion. Maximum vari- ation end-to-end is 0.076 mm ( .003 in.), side-to-side 0.051 mm (.002).
ENGINE 5.9L DIESEL
9 - 301
Visually inspect the cylinder head bolts for dam- aged threads, corroded/pitted surfaces, or a reduced diameter due to bolt stretching.
If the bolts are not damaged, their “free length” should be measured using the cap screw stretch gauge provided with the replacement head gasket. Place the head of the bolt against the base of the slot and align the bolt with the straight edge of gauge (Fig. 14). If the end of the bolt touches the foot of the gauge, the bolt must be discarded. The maximum bolt free length is 132.1 mm (5.200 in.).
