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Fig.14HeadBoltStretchGauge
INSPECTION—CROSSHEADS
Inspect the crossheads for cracks and/or excessive wear on rocker lever and valve tip mating surfaces (Fig. 15). Replace any crossheads that exhibit abnor- mal wear or cracks.
Fig.13CylinderHeadCombustionDeckFace
1 - STRAIGHT EDGE 2 - FEELER GAUGE
Fig.15InspectingCrossheadforCracks
ENGINE 5.9L DIESEL
9 - 302
CYLINDER HEAD (Continued) INSPECTION—PUSHRODSInspect the push rod ball and socket for signs of scoring. Check for cracks where the ball and the socket are pressed into the tube (Fig. 16).
Roll the push rod on a flat work surface with the socket end hanging off the edge (Fig. 17). Replace any push rod that appears to be bent.
DR
(b) Back off 360 degrees in sequence (c) Torque bolts to 105 N·m (77 ft. lbs.) (d) Re-check all bolts to 105 N·m (77 ft. lbs.) (e) Tighten all bolts an additional 1⁄4 turn (90°)
Fig.16InspectingPushRodforCracks
Fig.18CylinderHeadBoltTorqueSequence
(4) Install push rods into their original locations (Fig. 19). Verify that they are seated in the tap- pets.
Fig.17InspectingPushRodforFlatness
INSTALLATION
WARNING: THE OUTSIDE EDGE OF THE HEAD GASKET IS VERY SHARP. WHEN HANDLING THE NEW HEAD GASKET, USE CARE NOT TO INJURE YOURSELF.
(1) Install a new gasket with the part number side
up, and locate the gasket over the dowel sleeves.
(2) Using an engine lifting crane, lower the cylin-
der head onto the engine.
(3) Lightly lubricate head bolts with engine oil and install. Using the sequence shown in (Fig. 18), tighten bolts in the following steps:
(a) Torque bolts to 70 N·m (52 ft. lbs.)
Fig.19PushRodInstallation
(5) Lubricate valve stem tips and install the cross-
heads in their original locations.
(6) Lubricate the rocker arms and pedestals and install them in their original locations (Fig. 20). Install the bolts and torque them to 36 N·m (27 ft. lbs.).
(7) Verify that the valve lash settings are main- tained (Refer to 9 - ENGINE/CYLINDER HEAD/IN- TAKE/EXHAUST VALVES & SEATS - STANDARD PROCEDURE).
(8) Inspect rocker housing gasket for cuts and proper installation into groove. Replace if damaged.
DR CYLINDER HEAD (Continued)
ENGINE 5.9L DIESEL
9 - 303
(d) Install fuel line brace bolts-to-intake mani-
fold finger tight.
Nm ( 22 ft. lbs.).
(22 ft. lbs.)
(22 ft. lbs.).
(e) Hand tighten fuel pump to fuel rail line. (f) Torque fuel line nuts at cylinder head to 30
(g) Torque fuel line nuts at fuel rail to 30 Nm
(h) Torque fuel pump to fuel rail line to 30 Nm
(i) Torque fuel drain banjo bolt at pressure lim- iting valve and front of fuel filter housing to 24 Nm (18 ft. lbs.).
(j) Torque fuel line brace bolts to 24 N·m (18 ft.
lbs.).
(k) Torque rail bolts to 24 Nm (18 ft. lbs.). (l) Connect fuel pressure sensor.
(20) Install the engine lift bracket at the rear of
cylinder head. Torque to 77 N·m (57 ft. lbs.).
(21) Reposition number 6 fuel
line shield and
torque to 43 N·m (32 ft. lbs.).
(22) Install the fuel filter to injection pump low pressure line. Inspect and replace sealing washers if necessary. Torque banjo bolts to 24 N·m (18 ft. lbs.). (23) Connect fuel return line at back of cylinder
head hand tight.
(24) Connect fuel return line at filter housing hand
(25) Torque banjo connections at cylinder head and
fuel filter housing to 24 Nm (18 ft. lbs.)
(26) Install bracket
to rear of
filter housing.
Torque to 24 Nm (18 ft. lbs.).
(27) Using new gaskets,
install the intake grid heater and air inlet housing. Torque bolts to 24 N·m (18 ft. lbs.).
(28) Install wire harness P-clip and push on clip to
air inlet housing.
(29) Connect engine oil level indicator tube at fuel
filter housing and at air inlet housing.
(30) Connect the APPS connector. (31) Install the APPS assembly to the cylinder head bracket and torque bolts to 24 N·m (18 ft. lbs.).
(32) Install the throttle linkage cover. (33) Install the charge air cooler-to-air inlet hous- ing duct assembly. Torque all clamps to 11 N·m (100
in. lbs.).(34) Connect intake grid heater wires. (35) Secure engine harness to front of cylinder
head with bolt at four locations.
(36) Connect engine coolant temperature sensor
(37) Connect radiator upper hose to thermostat
(38) Rotate generator into position. Install upper
bolt and torque upper and lower bolts.
(39) Install wire harness push-on clip below
Fig.20RockerArmandPedestalRemoval
1 - ROCKER ARM 2 - PEDESTAL
(9) Install rocker housing and bolts. Tighten to 24
tight.
Nm (18 lb. ft.).
TEM/FUEL INSTALLATION).
(10) Install fuel injector(Refer to 14 - FUEL SYS-
INJECTION/FUEL
INJECTOR
(11) Install fuel injector tube and fuel injector tube
nut. Torqu to 50 N·m (37 ft. lbs.).
(12) Install injector harness nuts. Tighten to 1.5
Nm (13 lb. in.).
(13) Install cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
(14) Install wire harness P-clip to cylinder head
behind filter housing 24 N·m (18 ft. lbs.).
(15) Connect the IAT and MAP sensor connector. (16) Install the fuel filter canister assembly and
torque mounting bolts to 24 N·m (18 ft. lbs.).
(17) Connect fuel lift pump, WIF sensor, and fuel
(18) Remove the engine lift bracket at rear of cyl-
heater.
inder head.
CAUTION: Failure to follow procedure will result in fuel leaks and/or fuel system failure.
(19) Install the fuel rail and high pressure
fuel lines as follows:
(a) Hand tighten fuel rail bolts. (b) Hand tighten fuel drain line to pressure lim-
iting valve. Hand tighten at fuel filter housing.
(c) Hand tighten fuel rail-to-cylinder head lines.
connector.
housing.
bracket.
ENGINE 5.9L DIESEL
9 - 304
CYLINDER HEAD (Continued)(40) Install wire harness P-clip to top of bracket. (41) Install fan support and torque to 32 N·m (24
(42) Install cooling fan/drive and torque to 33 N·m
ft. lbs.).
(24 ft. lbs.).
(43) Install accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(44) Install exhaust manifold/turbocharger assem- bly, using new gaskets. Start all bolts/spacers by hand. Torque bolts to 43 N·m (32 ft. lbs.).
(45) Install exhaust manifold heat shield. Torque
to 24 N·m (18 ft. lbs.).
(46) Install exhaust bolt retention straps across
cylinders 5 & 6.
8 N·m (71 in. lbs.).
(47) Connect turbocharger oil drain tube. Torque to
(48) Perform the turbocharger pre-lube procedure. Refer to Group 11, Exhaust System and Turbo- charger for the correct procedure.
(49) Connect
the turbocharger oil supply line.
Torque to 24 N·m (18 ft. lbs.).
(50) Install air cleaner housing and duct. (51) Connect air inlet temperature/pressure sensor. (52) Raise vehicle on hoist. (53) Install exhaust pipe to turbocharger elbow.
Torque bolts to 8 N·m (72 in. lbs.).
(54) Lower vehicle. (55) Fill engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(56) Start engine and check for leaks.
CYLINDER HEAD COVER(S)
REMOVAL
REMOVAL—CYLINDER HEAD COVER
(1) Disconnect both battery negative cables. (2) Remove oil fill cap. (3) Remove the breather cover. (4) Disconnect
the breather hose and breather
drain tube from the breather housing.
(5) Remove cylinder head cover bolts. (6) Remove the cylinder head cover.
REMOVAL—ROCKER HOUSING
(1) Remove cylinder head cover as outlined in this
(2) Disconnect rocker housing injector harness con-
section.
nectors.
(3) Remove injector harness nuts from injectors. (4) Remove rocker housing bolts. (5) Remove rocker housing and gasket.
DR
CLEANING
Using a suitable solvent, Clean and dry gasket mating surfaces on cylinder head and rocker housing. Wipe gasket dry and inspect for re-use.
INSPECTION
The cylinder head cover gasket, rocker hous- ing gasket, are reusable. However, should cracks, nicks, or tears be present in the rubber/silicone con- struction, should be replaced. Also replace gasket if it is no longer flexi- ble. Inspect o-rings on cylinder head cover bolts.
the defective
components
INSTALLATION
INSTALLATION—CYLINDER HEAD COVER
(1) Inspect cylinder head cover gasket for cuts and
proper installation in groove. Replace if damaged.
(2) Position cylinder cover on top of rocker hous-
ing.
(18 ft. lbs.).
(3) Install bolts. (4) Starting with the center bolt, torque to 24 N·m
(5) Install breather hose to breather. (6) Install breather drain hose to breather. (7) Install breather cover and wire harness clip.
Torque to 24 N·m (18 ft. lbs.).
INSTALLATION—ROCKER HOUSING
(1) Inspect rocker housing gasket for cuts, nicks, or tears. Replace if damaged or if gasket has come out of groove.
(2) Inspect rocker housing gasket for proper instal- lation in groove. Gasket bead must be centered in groove. A gasket bead that is tilted to the side will cause an oil leak.
(3) Install Tool XXXX guide pins (or equivalent) into the cylinder head at rocker housing bolt loca- tions #1 and #5.
(4) Install the rocker hoiusing over the guide pins. Carefully gyide the rocker housing evenly down onto the cylinder head.
(5) With guide pins in place,
install remaining
rocker housing bolts and tighten finger tight.
(6) Remove guide pins and install
remaining
rocker housing bolts finger tight.
(7) Install rocker housing and bolts. Torque bolts,
working from center out, to 24 Nm (18ft. lbs.).
(8) Install injector harness nuts to injector sole-
noid. Torque to 1.5 Nm (13 in. lbs.).
(9) Connect rocker housing injector harness con-
nections.
DR
ENGINE 5.9L DIESEL
9 - 305
INTAKE/EXHAUST VALVES & SEATS DESCRIPTION
The valves are made of heat resistant steel, and have chrome plated stems to prevent scuffing. The intake and exhaust valves are both similar in head diameter and overall length, but they have unique face angles which makes them non-interchangeable. The valves are distinguished by unique dimples on the exhaust valve head (Fig. 21).
The exhaust valve springs are made from high strength, chrome silicon steel. The exhaust valve springs are also exhaust brake compatible.
Fig.21ValveIdentification
1 - INTAKE VALVES 2 - EXHAUST VALVES
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVES, GUIDES AND SPRINGS
REMOVAL
(1) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(2) Support cylinder head on stands, or install head bolts upside down (through combustion surface side) to protect injector tips from damage from work bench.
(3) Install the valve spring compressor mounting
base as shown in (Fig. 22).
(4) Install the compressor top plate, washer, and nut. Using a suitable wrench, tighten the nut (clock- wise) to compress the valve springs (Fig. 23) and remove the locks.
(5) Rotate the compressor nut counter-clockwise to relieve tension on the springs. Remove the spring compressor.
(6) Remove the retainers, springs, valve seals (if necessary), and valves (Fig. 24). Arrange or number all components so they can be installed in their orig- inal locations.
(7) Repeat the procedure on all cylinders to be ser-
viced.
Fig.22SpringCompressorMountingBase—Partof
1 - COMPRESSOR MOUNTING BASE
Tool8319–A
Fig.23CompressingValveSpringswithTool
8319–A
1 - SPECIAL TOOL 8319
CLEANING
Clean the valve stems with crocus cloth or a Scotch-Brite™ pad. Remove carbon with a soft wire brush. Clean valves, springs, retainers, and valve retaining locks in a suitable solvent. Rinse in hot water and blow dry with compressed air.
ENGINE 5.9L DIESEL
9 - 306
INTAKE/EXHAUST VALVES & SEATS (Continued)DR
Measure the valve stem diameter in three places
as shown in (Fig. 26).
Fig.24ValveSpring,Seal,andRetainers
1 - VALVE RETAINING LOCKS 2 - VALVE 3 - SEAL 4 - SPRING 5 - RETAINER
INSPECTION
Visually inspect the valves for abnormal wear on the heads, stems, and tips. Replace any valve that is worn out or bent (Fig. 25).
Fig.25VisuallyInspectValvesforAbnormalWear
Fig.26MeasureValveStemDiameter
VALVE STEM DIAMETER 6.96 mm (0.2740 in.) MIN
7.010 mm (0.2760 in.) MAX
Measure the cylinder head valve guide bore (Fig. 27).
VALVE GUIDE BORE SPECIFICATIONS
VALVE GUIDE BORE SPECIFICATIONS
Valve guide bore diameter
Installed valve guide depth Intake
Exhaust
Min. Max.
7.027 mm (0.2767 in.) 7.077 mm (0.2786 in.)
Min. Max.
0.584 mm ( 0.023 in.) 1.092 mm ( 0.043 in.)
Min. Max.
0.965 mm ( 0.028 in.) 1.473 mm (0.058 in.)
Fig.27MeasureValveGuideBore
DR INTAKE/EXHAUST VALVES & SEATS (Continued)
Measure valve margin (rim thickness) (Fig. 28).
ENGINE 5.9L DIESEL
9 - 307
Fig.28MeasureValveMargin(RimThickness)
VALVE MARGIN (RIM THICKNESS)
0.79 mm (0.031 in.) MIN.
Measure the valve spring free length and maxi-
mum inclination (Fig. 29).
Fig.30TestingValveSpringwithToolC-647
1 - SPECIAL TOOL C-647
Fig.29MeasureValveSpringFreeLengthandMax.
Inclination
APPROXIMATE VALVE SPRING FREE LENGTH
47.75 mm (1.88 in.)
MAX INCLINATION
1.5 mm (.059 in.)
Test valve spring force with tool C-647 (Fig. 30). Specification 72.0 — 80.7 lbs. when compressed to 35.33 mm (1.39 in.).
INSTALLATION
(1) Install new valve seals. The yellow seals are for the intake valves and the green seals are for the exhaust valves.
(2) Install the valves in their original postion. The exhaust valves are identified by a dimple on the valve head (Fig. 31).
(3) Install the valve springs and retainer. (4) Install the valve spring compressor tool 8319–A
as shown in (Fig. 22) and (Fig. 23).
Fig.31ValveIdentification
1 - INTAKE VALVES 2 - EXHAUST VALVES
(5) Compress the valve springs and install the
valve retaining locks (Fig. 24).
(6) Remove the compressor and repeat the proce-
dure on the remaining cylinders.
(7) Install new o-ring and sealing washer on injec-
(8) Lubricate o-ring and injector bore. (9) Verify sealing washer (shim) was removed with
(10) Install
injector with fuel
injector connector
port facing intake manifold.
(11) Install hold-down bolt. Torque to 10 Nm (89
(12) Install fuel injector connector and connector
nut. Torque nut to 50 Nm (36.8 ft. lbs.).
(13) Install
the cylinder head (Refer
to 9 -
ENGINE/CYLINDER HEAD - INSTALLATION).
tor.
old injector.
in. lbs.).
ENGINE 5.9L DIESEL
9 - 308
INTAKE/EXHAUST VALVES & SEATS (Continued) STANDARD PROCEDURE - VALVE LASH ADJUSTMENT AND VERIFICATIONNOTE: To obtain accurate readings, valve lash mea- surements AND adjustments should only be per- formed when the engine coolant temperature is less than 60° C (140° F).
DR
The 24–valve overhead system is a “low-mainte- nance” design. Routine adjustments are no longer necessary, however, measurement should still take place when trouble-shooting performance problems, or upon completion of a repair that includes removal and installation of the valve train components or injectors.
(1) Disconnect battery negative cables. (2) Remove cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(3) Using the crankshaft barring tool #7471–B, rotate crankshaft to align damper TDC mark to 12:00 o’clock position.
(a) If both number one cylinder rocker levers are
loose, continue to next step.
(b) If both number one clylinder rocker levers
are not loose, rotate crankshaft 360 degrees. (4) With the engine in this position, valve lash can be measured at the following rocker arms: INTAKE 1–2–4 / EXHAUST 1–3–5. Measure the valve lash by inserting a feeler gauge between the rocker arm socket and crosshead (Fig. 32). Refer to VALVE LASH LIMIT CHART for the correct specifications. If the measurement falls within the limits, adjust- ment/resetting is not necessary. If measurement finds the lash outside of the limits, adjustment/re- setting is required.
VALVE LASH LIMIT CHART
INTAKE
EXHAUST
0.152 mm ( 0.006 in.)
0.381 mm (0.015 in.)
MIN.
MIN.
0.381 mm (0.015 in.)
0.762 mm (0.030 in.)
MAX.
MAX.
note: If measured valve lash falls within these specifications, no adjustment/reset is necessary. Engine operation within these ranges has no adverse affect on performance, emissions, fuel economy or level of engine noise.
Fig.32MeasuringValveLash-Typical
1 - INTAKE 2 - FEELER GAUGE 3 - EXHAUST
(5) If adjustment/resetting is required, loosen the lock nut on rocker arms and turn the adjusting screw until the desired lash is obtained: † INTAKE 0.254 mm (0.010 in.) † EXHAUST 0.508 mm (0.020 in.) Tighten the lock nut to 24 Nm (18 ft. lbs.) and re-check the valve lash.
(6) Using the crankshaft barring tool, rotate the to align the
crankshaft one revolution (360°) damper TDC mark to the 12 o’clock position.
(7) With the engine in this position, valve lash can be measured at the remaining rocker arms: INTAKE 3–5–6 / EXHAUST 2–4–6. Use the same method as above for determining whether adjustment is neces- sary, and adjust those that are found to be outside of the limits.
(8) Install the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
(9) Connect the battery negative cables.
REMOVAL - VALVE SPRINGS AND SEALS (1) Disconnect the battery negative cables. (2) Remove the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(3) Disconnect rocker housing injector harness con-
nector. Remove all injector harness solenoid nuts.
(4) Remove injector(s) for cylinder(s) to be serviced.
Refer to Group 14 for injector removal.
(5) Remove the rocker housing. (6) Remove the rocker arms and crossheads from the cylinder(s) to be serviced. Mark each component so they can be installed in their original position.
(7) Using the crankshaft barring tool #7471–B (Fig. 33), rotate the engine to position the damper
DR INTAKE/EXHAUST VALVES & SEATS (Continued)
ENGINE 5.9L DIESEL
9 - 309
35) to compress the valve springs and remove the collets.
(e) Rotate the compressor nut counter-clockwise to relieve tension on springs. Remove spring com- pressor.
(f) Remove and replace retainers, springs, and
seals as necessary.
(g) Do not rotate the engine until
the
springs and retainers are re-installed.
(h) Install seals, springs and retainers. Install spring compressor, compress valve springs and install the collets.
(i) Release the spring tension and remove the compressor. Verify that the collets are seated by tapping on the valve stem with a plastic hammer. (12) Using the crankshaft barring tool, rotate the engine until the next crankshaft damper paint mark aligns with the mark you placed on the cover. In this position, cylinders #2 and #5 can be serviced.
(13) Repeat the valve spring compressing proce- dure previously performed and service the retainers, springs, and seals as necessary.
(14) Using the crankshaft barring tool, rotate the engine until the next crankshaft damper paint mark aligns with the mark you placed on the cover. In this position, cylinders #3 and #4 can be serviced.
(15) Repeat the spring compressing procedure pre- viously performed and service the retainers, springs, and seals as necessary.
mark in the 12 o’clock position. At this engine posi- tion, cylinders #1 and #6 can be serviced.
(8) Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(9) With the damper TDC mark in the 12 o’clock position, add a paint mark anywhere on the gear housing cover next to the crankshaft damper. Place another mark on the vibration damper in alignment with the mark you just made on the cover.
(10) Divide the crankshaft damper
into three
equally sized segments as follows:
(a) Using a tape measure, measure the circum- ference of the crankshaft damper and divide the measurement by three (3).
(b) Measure that distance in a counter-clockwise direction from the first balancer mark and place another mark on the balancer.
(c) From the second damper mark, again mea- sure in a counter-clockwise direction and place a mark on the damper at the same distance you measured when placing the second damper mark. The damper should now be marked in three equally spaced locations and the damper TDC mark should be in the 12 o’clock position.
(d) Remove injectors, fuel lines, and high pres- sure connectors for every cylinder that requires repair.
Fig.33RotatingEnginewithBarringTool-Typical 1 - REAR FLANGE 2 - BARRING TOOL
(11) Compress the valve springs at cyls. #1 and #6
(a) Remove bolts and injector hold-down clamp. (b) Using miller special tool #9010, remove injec-
as follows:
tor.
Fig.34SpringCompressorMountingBase—Partof
1 - COMPRESSOR MOUNTING BASE
Tool8319–A
INSTALLATION
(1) Install rocker housing. (2) Install
fuel
injectors and high pressure fuel
(3) Lubricate the valve tips and install the cross-
heads in their original locations.
(c) Install the valve spring compressor mounting
lines.
base as shown in (Fig. 34).
(d) Install the top plate, washer, and nut. Using a suitable wrench tighten the nut (clock-wise) (Fig.
ENGINE 5.9L DIESEL
9 - 310
INTAKE/EXHAUST VALVES & SEATS (Continued)DR
der head. Mark the arms and pedestals so they can be installed in their original position.
CAUTION: When removing the rocker arms, the sockets (Fig. 37) may come loose and fall into the engine. Make sure they stay with the arm upon removal/installation.
(4) Lift the push rod(s) up and out of the engine (Fig. 38). Mark them so they can be installed in their original position.
NOTE: The #5 cyl. intake and exhaust and #6 cyl. intake and exhaust push rods must be raised through the provided cowl panel access holes.
(5) Lift the crosshead(s) off of the valve stems. Mark them so they can be installed in their original position.
Fig.35CompressingValveSpringswithTool
8319–A
1 - SPECIAL TOOL 8319
(4) Lubricate the crossheads and push rod sockets and install the rocker arms and pedestals in their original locations. Tighten bolts to 36 N·m (27 ft. lbs.) torque.
(5) Verify valve lash adjustment (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST VALVES & SEATS - STANDARD PROCEDURE). (6) Install cylinder head cover and reusable gasket (Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN- DER HEAD COVER(S) - INSTALLATION).
(7) Connect battery negative cables.
ROCKER ARM / ADJUSTER ASSY DESCRIPTION
The unique intake and exhaust rocker arms have their own rocker shafts and are lubricated by pas- sages intersecting the cylinder block main oil rifle. Crossheads are used, which allow each rocker arm to operate two valves.
The solid push rods are hardened at the rocker arm and tappet contact areas for superior strength and durability.
REMOVAL
(1) Disconnect the battery negative cables. (2) Remove cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(3) Remove the rocker arm/pedestal fasteners (Fig. 36) and remove rocker arm and pedestal from cylin-
Fig.36RockerArmandPedestalRemoval
1 - ROCKER ARM 2 - PEDESTAL
CLEANING
Clean all components in a suitable solvent. If nec- essary, use a wire brush or wheel to remove stubborn deposits. Rinse in hot water and blow dry with com- pressed air. Inspect oil passages in rocker arms and pedestals. Apply compressed air to lubrication orifices to purge contaminants.
DR ROCKER ARM / ADJUSTER ASSY (Continued)
ENGINE 5.9L DIESEL
9 - 311
Fig.37RockerArmAssemblyIdentification
1 - NUT 2 - ADJUSTING SCREW 3 - ROCKER SHAFT 4 - RETAINER 5 - SOCKET
Fig.39MeasuringRockerArmBore
ROCKER ARM BORE (MAX.)
22.027 mm (.867 in.)
Fig.40MeasuringRockerArmShaft
ROCKER ARM SHAFT (MIN.)
21.965 mm (.865 in.)
Fig.38PushRodRemoval/Installation
INSPECTION
Rocker Arms
(1) Remove rocker shaft and inspect for cracks and excessive wear in the bore or shaft. Remove socket and inspect ball insert and socket for signs of wear. Replace retainer if necessary.
Measure the rocker arm bore and shaft (Fig. 39)
(Fig. 40).
Push Rods
Inspect the push rod ball and socket for signs of scoring. Check for cracks where the ball and the socket are pressed into the tube (Fig. 41).
Roll the push rod on a flat work surface with the socket end hanging off the edge (Fig. 42). Replace any push rod that appears to be bent.
Fig.41InspectingPushRodforCracks
ENGINE 5.9L DIESEL
9 - 312
ROCKER ARM / ADJUSTER ASSY (Continued)DR
ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER BLOCK REFACING
(1) The combustion deck can be refaced twice. The first reface should be 0.25 mm (0.0098 inch). If addi- tional refacing is required, an additional 0.25 mm (0.0098 inch) can be removed. Total allowed refacing is 0.50 mm (0.0197 inch) - (Fig. 44).
Fig.42InspectingPushRodforFlatness
Crossheads
Inspect the crossheads for cracks and/or excessive wear on rocker lever and valve tip mating surfaces (Fig. 43).
Fig.43InspectingCrossheadforCracks
INSTALLATION
(1) If previously removed, install the push rods in their original location. Verify that they are seated in the tappets.
(2) Lubricate the valve tips and install the cross-
heads in their original locations.
(3) Lubricate the crossheads and push rod sockets and install the rocker arms and pedestals in their original locations. Tighten bolts to 36 N·m (27 ft. lbs.) torque.
(4) Verify valve lash adjustment (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST VALVES & SEATS - STANDARD PROCEDURE). (5) Install cylinder head cover and reusable gasket (Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN- DER HEAD COVER(S) - INSTALLATION).
(6) Connect battery negative cables.
Fig.44RefacingDimensionsoftheCylinderBlock
CYLINDER BLOCK REFACING DIMENSIONS
DIMENSION (A(
1st Reface 2nd Reface Dim (A) Total
Dim. 9B9 (STD.)
1st Reface
2nd Reface
0.25mm 0.25mm 0.50 mm
(0.0098 in.) (0.0098 in.) (0.0197 in.)
DIMENSION (B(
323.00 mm ± 0.10
322.75 mm ± 0.10
322.50 mm ± 0.10
mm
mm
mm
(12.7165 in. ±
0.0039 in.)
(12.7067 in. ±
0.0039 in.)
(12.6968 in. ±
0.0039 in.)
(2) The upper right corner of the rear face of the block must be stamped with a X when the block is refaced to 0.25 mm (0.0098 inch). A second X must be stamped beside the first when the block is refaced to 0.50 mm (0.0197 inch) - (Fig. 45).
DR ENGINE BLOCK (Continued)
ENGINE 5.9L DIESEL
9 - 313
Fig.45StampBlockafterReface
(3) Consult the parts catalog for the proper head gaskets which must be used with refaced blocks to ensure proper piston-to-valve clearance.
STANDARD PROCEDURE - CYLINDER BORE - DE-GLAZE
(1) New piston rings may not seat in glazed cylin-
der bores.
(2) De-glazing gives the bore the correct surface finish required to seat the rings. The size of the bore is not changed by proper de-glazing.
(3) Cover the lube and tappet holes in the top of
the block with waterproof tape.
(4) It crankshaft is installed, wrap connecting rod journals with clean cloth. Cover cloth with water- proof tape.
(5) A correctly honed surface will have a cross- hatch appearance with the lines at 15° to 25° angles (Fig. 46). For the rough hone, use 80 grit honing stones. To finish hone, use 280 grit honing stones.
Fig.46CylinderBoreCrosshatchPattern
(6) Use a drill, a fine grit Flex-hone and a mixture of equal parts of mineral spirits and SAE 30W engine oil to de-glaze the bores.
(7) The crosshatch angle is a function of drill speed and how fast the hone is moved vertically (Fig. 47).
(8) Vertical strokes MUST be smooth continuous
passes along the full length of the bore (Fig. 47).
Fig.47De-GlazingDrillSpeedandVerticalSpeed (9) Inspect the bore after 10 strokes. (10) Use a strong solution of hot water and laun- dry detergent to clean the bores. Clean the cylinder bores immediately after de-glazing.
(11) Rinse the bores until the detergent is removed
and blow the block dry with compressed air.
(12) Check the bore cleanliness by wiping with a white, lint free, lightly oiled cloth. If grit residue is still present, repeat the cleaning process until all res- idue is removed. Wash the bores and the complete block assembly with solvent and dry with compressed air. Place a clean shop towel around the top main bearing saddle to deflect water and residue from pis- ton cooling nozzels. Remove directed piston cooling nozzles if installed.
(13) Be sure to remove the tape covering the lube holes, rod journals, and piston cooling nozzles after the cleaning process is complete.
STANDARD PROCEDURE—CYLINDER BORE REPAIR
methods:
Cylinder bore(s) can be repaired by one of two † Method 1:—Over boring and using oversize pis- † Method 2:—Boring and installing a repair sleeve
tons and rings.
to return the bore to standard dimensions.
METHOD 1—OVERSIZE BORE
Cylinder bore(s) can be repaired by one of two
methods:
Oversize pistons and rings are available in two sizes - 0.50 mm (0.0197 inch) and 1.00 mm (0.0393
inch).Any combination of standard, 0.50 mm (0.0197
inch) or 1.00 mm (0.0393 inch) overbore may be used in the same engine.ENGINE 5.9L DIESEL
9 - 314
ENGINE BLOCK (Continued)If more than 1.00 mm (0.0393 inch) overbore is needed, a repair sleeve can be installed (refer to Method 2—Repair Sleeve).
Cylinder block bores may be bored twice before use of a repair sleeve is required. The first bore is 0.50
mm (0.0197 inch) oversize. The second bore is 1.00
mm (0.0393 inch) oversize.After boring to size, use a honing stone to chamfer
the edge of the bore.
CYLINDER BORE DIMENSION CHART
DESCRIPTION
MEASUREMENT
BORING DIAMETER
1st. REBORE - 102.469
DIMENSION
mm (4.0342 in.)
HONING DIAMETER
DIMENSIONS
CHAMFER
DIMENSIONS
2nd. REBORE - 102.969
mm (4.0539 in.)
STANDARD - 102.020 ±
0.020 mm (4.0165 ±
0.0008 in.)
1st. REBORE - 102.520
± 0.020 mm (4.0362 ±0.0008 in.)
2nd. REBORE - 103.020
± 0.020 mm 4.0559 ±
0.0008 in.)
Approx. 1.25 mm (0.049
in.) by 15°
A correctly honed surface will have a crosshatch appearance with the lines at 15° to 25° angles with the top of the cylinder block (Fig. 48). For the rough hone, use 80 grit honing stones. To finish hone, use 280 grit honing stones.
Fig.48CrosshatchPatternofRepairedSleeve(s) A maximum of 1.2 micrometer (48 microinch) sur-
face finish must be obtained.
After finish honing is complete, immediately clean the cylinder bores with a strong solution of laundry detergent and hot water.
After rinsing, blow the block dry. Check the bore cleanliness by wiping with a white, lint-free, lightly- oiled cloth. There should be no grit residue present.
DR
If the block is not to be used right away, coat it
with a rust- preventing compound.
METHOD 2—REPAIR SLEEVE
If more than a 1.00 mm (0.03937 inch) diameter oversize bore is required, the block must be bored and a repair sleeve installed.
Bore the block cylinder bore to 104.500-104.515
mm (4.1142-4.1148 inch) - (Fig. 49).
Repair sleeves can be replaced by using a boring bar to bore out the old sleeve. DO NOT cut the cyl- inder bore beyond the oversize limit.
Fig.49BlockBoreforRepairSleeveDimensions 1 - BORE DIAMETER 2 - STEP DIMENSION
REPAIR SLEEVE BLOCK REBORE
DIMENSIONS CHART
BORE DIAMETER 104.500 + 0.015 mm (4.1142 + 0.0006 in.)
STEP DIMENSION 6.35 mm (0.25 in.)
After machining the block for the new repair sleeve, thoroughly clean the bore of all metal chips, debris and oil residue before installing the sleeve.
Cool the repair sleeve(s) to a temperature of -12°C (10°F) or below for a minimum of one hour. Be ready to install the sleeve immediately after removing it from the freezer.
Apply a coat of Loctite 620, or equivalent to the
bore that is to be sleeved.
Wear protective gloves to push the cold sleeve into
the bore as far as possible.
DR ENGINE BLOCK (Continued)
Using a sleeve driver, drive the sleeve downward until it contacts the step at the bottom of the bore (Fig. 50).
Fig.50SleeveInstallation
1 - SLEEVE DRIVER 2 - SLEEVE 3 - CONTACT
A sleeve driver can be constructed as follows (Fig.
51).
Fig.51SleeveDriverConstruction
1 - DRIVE 2 - HANDLE
SLEEVE DRIVER CONSTRUCTION
SPECIFICATION CHART
ITEM
MEASUREMENT
127 mm (5 in.) 38 mm (1.5 in.)
6.35 mm (0.25 in.)
25.4 mm (1 in.)
101 mm (3.976 in.)
107.343 mm (4.226 in.)
ENGINE 5.9L DIESEL
9 - 315
Set up a boring bar and machine the sleeve to
101.956 mm (4.014 inch).
After removing the boring bar, use a honing stone
to chamfer the corner of the repair sleeve(s).
SLEEVE MACHINING DIMENSIONS CHART
ITEM
MEASUREMENT
SLEEVE PROTRUSION
MIN. - FLUSH WITH
SLEEVE DIAMETER SLEEVE CHAMFER
BLOCK
MAX. - 0.050 mm
(0.0019 in.)
101.956 mm (4.014 in.)
APPROX. 1.25 mm (0.049 in.) by 15°
A correctly honed surface will have a crosshatch appearance with the lines at 15° to 25° angles with the top of the cylinder block. For the rough hone, use 80 grit honing stones. To finish hone, use 280 grit honing stones.
Finished bore inside dimension is 102.020 ±0.020
mm (4.0165 ±0.0008 inch).
A maximum of 1.2 micrometer (48 microinch) sur-
face finish must be obtained.
After finish honing is complete, immediately clean the cylinder bores with a strong solution of laundry detergent and hot water.
After rinsing, blow the block dry with compressed
air.
Wipe the bore with a white, lint-free, lightly oiled
cloth. Make sure there is no grit residue present.
Apply a rust-preventing compound if the block will
not be used immediately.
A standard diameter piston and a piston ring set
must be used with a sleeved cylinder bore.
STANDARD PROCEDURE—CAM BORE REPAIR For standard bushings, not oversized, maximum front and rear cam bushing bore diameter is 59.248
mm. (2.3326 in.). DO NOT bore the intermediate cam bore to the front cam bore oversize dimensions. Max- imum front and rear camshaft bushing installed diameter (2.1318 in.). Minimum installed diameter is 54.083 mm. (2.1293 in.). Maxi- mum intermediate camshaft bore diameter is 54.164
mm. (2.1324 in.).is 54.147 mm.
A surface finish of 2.3 micrometers (92 microinch) must be maintained. Not more than 20% of an area of any one bore may be 3.2 micrometers (126 micro- inch).
Camshaft bores can be repaired individually. It is not necessary to repair undamaged cam bores in order to repair individually damaged cam bores. The
ENGINE 5.9L DIESEL
9 - 316
ENGINE BLOCK (Continued)standard front bushing cannot be used to repair intermediate bores.
Install all cam bushings flush or below the front and rear cam bore surface. The front camshaft bush- ing should be installed flush with front face of block. The rear camshaft bushing should be installed flush with rear face of block. The oil hole must align to allow a 3.2 mm (0.125 inch) rod to pass through freely (Fig. 52).
Fig.52OilHoleAlignment
1 - CAMSHAFT BUSHING
INSPECTION
Measure the combustion deck face using a straight edge and a feeler gauge (Fig. 53). Cylinder block flat- ness: End-to-end 0.076 mm ( .003 in.). Maximum variation side-to-side 0.051 mm (.002 in.).
Inspect for any localized dips or imperfections. If the surface exceeds the limit,
(Refer to 9 - ENGINE/ENGINE BLOCK - STANDARD PROCE- DURE).
Fig.53CombustionDeckFaceMeasurement
1 - STRAIGHT EDGE 2 - FEELER GAUGE
DR
Inspect the cylinder bores for damage or excessive
wear.
Measure the cylinder bores (Fig. 54). If the cylin- der bores exceed the limit, (Refer to 9 - ENGINE/EN- GINE BLOCK - STANDARD PROCEDURE).
Fig.54CylinderBoreDiameter
BORE SPECIFICATIONS
BORE DIAMETER
Min. Max.
102.000 mm (4.0157 in.) 102.116 mm (4.0203 in.)
OUT OF ROUNDNESS
Max.
0.038 mm (0.0015 in.)
TAPER
Max.
0.076 mm (.003 in.)
Inspect the camshaft bores for scoring or excessive
wear.
wear.
Measure the camshaft bores (Refer to 9 - ENGINE
- SPECIFICATIONS).
If a bore exceeds the limit, (Refer to 9 - ENGINE/ ENGINE BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) - STANDARD PROCEDURE).
Inspect the tappet bores for scoring or excessive
Measure tappet bore from bottom of block. Mini- mum tappet bore diameter 16.000 mm (0.0630 in.). Maximum tappet bore 16.055 mm. (0.632 in.).
If out of limits, replace the cylinder block.
DR
ENGINE 5.9L DIESEL
9 - 317
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVAL—CAMSHAFT BEARINGS
If the NOTE: Measure the diameter of each bore. camshaft bore for the first or rear cam bushing is worn beyond the limit, install a new service bush- ing. Inspect the rest of the camshaft bores for dam- age or excessive wear.If the bores without a bushing are worn beyond the limit, the engine must be removed for machining and installation of ser- vice bushings. If badly worn, replace the cylinder block.
(1) Remove the camshaft (Refer to 9 - ENGINE/ ENGINE BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) - REMOVAL).
(2) Remove the bushing from the No.1 bore and
No.7 using a universal cam bushing tool.
(3) Mark the cylinder block so you can align the oil hole in the cylinder block with the oil hole in the bushing.
REMOVAL - CAMSHAFT
(1) Disconnect both battery negative cables. (2) Recover A/C refrigerant (if A/C equipped) (Refer to 24 - HEATING & AIR CONDITIONING/PLUMB- ING - STANDARD PROCEDURE).
(3) Raise vehicle on hoist. (4) Drain engine coolant into container suitable for re-use (Refer to 7 - COOLING - STANDARD PROCE- DURE).
(5) Lower vehicle. (6) Remove radiator upper hose. (7) Remove viscous fan/drive assembly and fan shroud (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(8) Disconnect
the coolant recovery bottle hose
from the radiator filler neck.
(9) Disconnect lower radiator hose from radiator
outlet.
(10) Automatic Transmission models: Discon- nect transmission oil cooler lines from front of radia- tor using Special Tool 6931 (unless equipped with finger-release disconnect).
(11) Remove radiator mounting screws and lift
radiator out of engine compartment.
(12) Remove upper radiator support panel. (13) If A/C equipped, disconnect A/C condenser
refrigerant lines.
cooler inlet and outlet.
(14) Disconnect charge air cooler piping from the
(15) Remove the two charge air cooler mounting
bolts.
(16) Remove charge air cooler (and A/C condenser
if equipped) from vehicle.
(17) Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(18) Remove accessory drive belt tensioner. (19) Remove the fan support/hub assembly. (20) Remove crankshaft damper and speed indica- tor ring (Refer to 9 - ENGINE/ENGINE BLOCK/VI- BRATION DAMPER - REMOVAL).
(21) Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar the sealing surfaces. Remove dust seal with cover.
(22) Using Special Tool 7471–B Crankshaft Bar- ring Tool, rotate the crankshaft to align the timing marks on the crankshaft and the camshaft gears.
(23) Remove the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(24) Remove the rocker arms, cross heads, and push rods (Fig. 55). Mark each component so they can be installed in their original positions.
NOTE: The #5 cylinder intake and the #6 cylinder intake and exhaust pushrods are removed by lifting them up and through the provided cowl panel access holes. Remove the rubber plugs to expose these relief holes.
Fig.55PushRodRemoval/Installation
(25) Raise the tappets as follows, using the wooden dowel rods (Fig. 57)provided with the Miller Tool Kit 8502.
(a) Insert the slotted end of the dowel rod into the tappet. The dowel rods for the rear two cylinders will have to be cut for cowl panel clearance. Press firmly to ensure that it is seated in the tappet.
ENGINE 5.9L DIESEL
9 - 318
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)DR
(b) Raise the dowel rod to bring the tappet to the top of its travel, and wrap a rubber band around the dowel rods (Fig. 57) to prevent the tap- pets from dropping into the crankcase.
(c) Repeat this procedure for the remaining cyl-
inders. (26) Verify that the camshaft timing marks are
aligned with the crankshaft mark (Fig. 56).
(30) Raise
engine
enough to allow camshaft
removal.
(31) Remove the camshaft, gear and thrust plate.
INSPECTION
Camshaft
(1) Inspect the valve lobes and bearing journals for cracks, pitting, scoring, or generally excessive wear. Replace any camshaft that exceeds the allowable lim- its.
(2) Measure the bearing journals and lobes (Fig.
58).
If Camshaft
CAUTION: lobes are worn, requiring camshaft replacement, it is necessary to replace the tappets also. (Refer to 9 - ENGINE/ENGINE BLOCK/ SOLID LIFTERS - REMOVAL).
CAMSHAFT DIMENSIONS
CAMSHAFT DIMENSIONS
Journal diameter (No.1 and No.7)
Min.
Max.
54.028 mm. (2.127 in.) 54.048 mm. (2.128 in.)
Journal diameter (No.2 through No.6) Min.
Max.
Diameter of peak of lobe
Intake Min.
Max
Exhaust
53.962 mm. (2.1245 in.) 54.013 mm. (2.1265 in.)
47.175 mm (1.857 in.) 47.855 mm.
Min.
Max.
45.632 mm. (1.797 in.) 46.312 mm. (1.823 in.)
Fig.56TimingMarkAlignment
Fig.57UseWoodenDowelRodstoSecureTappets
inPlace-Typical
(27) Remove the bolts from the thrust plate. (28) Remove engine mount through bolts. (29) Install engine support fixture special tool # 8534, and steel bracket/wing nut special tool # 8534A.
DR CAMSHAFT & BEARINGS (IN BLOCK) (Continued)
ENGINE 5.9L DIESEL
9 - 319
Fig.60InspectingOilHoleAlignment
1 - CAMSHAFT BUSHING
Camshaft Gear
Inspect the camshaft gear for cracks (gear and hub) (Fig. 61), and chipped/broken/fretted teeth (Fig. 62). If replacement is necessary, camshaft and gear are replaced as an assembly. (Refer to 9 - ENGINE/ ENGINE BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) - REMOVAL).
Fig.58Measuring
1 - VALVE LOBE 2 - CAMSHAFT JOURNAL
Camshaft Bushing/Bores
Camshaft bores No. 2–6 do not use a bushing. (1) Inspect the camshaft bushing and bores for
signs of excessive wear.
(2) Measure the camshaft bushing and bores (Fig. 59) with a telescoping bore gauge and micrometer. If out of specification, (Refer to 9 - ENGINE/ENGINE BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) - REMOVAL). (3) Inspect
the camshaft bushing oil holes for
alignment with cylinder block (Fig. 60).
Fig.61InspectCamshaftGearHubforCracks-
Typical
Fig.59MeasuringCamshaftBushingandBores
Fig.62InspectCamshaftGearforCracksand
Fretting-Typical
ENGINE 5.9L DIESEL
9 - 320
CAMSHAFT & BEARINGS (IN BLOCK) (Continued) Thrust PlateDR
(3) Install the camshaft and thrust plate. Align the
timing marks as shown (Fig. 64).
Inspect the camshaft thrust plate for excessive wear in the camshaft contact area. Measure thrust plate thickness using the CAMSHAFT THRUST PLATE THICKNESS CHART. Replace any thrust plate that falls outside of these specifications:
CAMSHAFT THRUST PLATE THICKNESS CHART
MIN. 9.34 mm (0.368 in.) MAX. 9.60 mm (0.378 in.)
INSTALLATION
INSTALLATION - CAMSHAFT BEARINGS
(1) Apply a coating of Loctitet 640 Adhesive to the backside of the new bushing. Avoid getting adhesive in the oil hole.
(2) Use a universal cam bushing installation tool and install the front bushing so that it is even with the front face of the cylinder block. The oil hole must be aligned. A 3.2 mm (0.128 inch) diameter rod must be able to pass through the hole. (Fig. 63).
(3) Install the rear camshaft bushing is flush with the rear face of the block. The oil hole must be aligned. A 3.2 mm (0.128 inch) diameter rod must be able to pass through the hole.
(4) Measure the installed bushings at the front and rear bores. The minimum inside diameter is 54.083 mm (2.1293 inch), and the maximum inside diameter is is 54.147 mm. (2.1318 in.).
Fig.63OilHoleAlignment
1 - CAMSHAFT BUSHING
INSTALLATION - CAMSHAFT
(1) Lubricate the camshaft bushing and bores with
fresh engine oil or suitable equivalent.
(2) Liberally coat the camshaft lobes, journals, and thrust washer with fresh engine oil or suitable equiv- alent.
CAUTION: When installing the camshaft, DO NOT push it in farther than it will go with the thrust washer in place.
Fig.64TimingMarkAlignment
(4) Install the thrust plate bolts and tighten to 24
N·m (18 ft. lbs.) torque.
(5) Measure camshaft back lash and end clearance.
BACKLASH — 0.075—0.250 mm
(0.003—0.013 inch)
CLEARANCE — 0.025—0.500 mm
(0.001—0.020 inch)
(6) Remove the wooden dowel rods and rubber
bands from the tappets.
(7) Lubricate the push rods with engine oil and install in their original location. Verify that they are seated in the tappets.
(8) Lubricate the valve tips with engine oil and
install the crossheads in their original locations.
(9) Lubricate the crossheads and push rod sockets with engine oil and install the rocker arms and ped- estals in their original locations. Tighten bolts to 36
N·m (27 ft. lbs.) torque.(10) Verify valve lash adjustment (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST VALVES & SEATS - STANDARD PROCEDURE). (11) Install the cylinder head cover and reusable gasket (Refer to 9 - ENGINE/CYLINDER HEAD/ CYLINDER HEAD COVER(S) - INSTALLATION).
(12) Install gear housing cover (Refer to 9 - ENGINE/ VALVE TIMING/GEAR HOUSING COVER - INSTAL- LATION). Install front crankshaft dust seal.
(13) Install the crankshaft damper with the speed to 9 - ENGINE/ENGINE
indicator BLOCK/VIBRATION DAMPER - INSTALLATION).
ring (Refer
DR CAMSHAFT & BEARINGS (IN BLOCK) (Continued)
ENGINE 5.9L DIESEL
9 - 321
(14) Install
the fan support/hub assembly and
tighten bolts to 33 N·m (24 ft. lbs.) torque.
(15) Install the power steering pump. (16) Install accessory drive belt tensioner. Torque
bolt to 43 Nm (43 ft. lbs.).
(17) Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(18) Install the charge air cooler (with a/c con- denser and auxiliary transmission oil if equipped) and tighten the mounting bolts to 2 N·m (17 in. lbs.) torque.
cooler,
(19) Connect charge air cooler inlet and outlet pipes. Tighten clamps to 11 N·m (95 in. lbs.) torque.
(20) Install the radiator upper support panel. (21) Close radiator petcock and lower the radiator into the engine compartment. Tighten the mounting bolts to 11 N·m (95 in. lbs.) torque.
(22) Raise vehicle on hoist. (23) Connect radiator lower hose and install clamp. (24) Connect transmission auxiliary oil cooler lines
(if equipped).
(25) Lower vehicle. (26) Install the fan shroud and tighten the mount-
ing screws to 6 N·m (50 in. lbs.) torque.
(27) Install
the electronically controlled viscous fan/drive assembly. Connect harness connector.(Refer to - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).
(28) Install the coolant recovery and windshield
washer fluid reservoirs to the fan shroud.
(29) Connect the coolant recovery hose to the radi-
ator filler neck.
(30) Add engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(31) Charge A/C system with refrigerant (if A/C equipped) (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING - STANDARD PROCEDURE).
(32) Connect the battery negative cables. (33) Start engine and check for engine oil and cool-
ant leaks.
CONNECTING ROD BEARINGS STANDARD PROCEDURE - CONNECTING ROD BEARING AND CRANKSHAFT JOURNAL CLEARANCE
(1) Measure the connecting rod bore with bearings removed and the bolts tightened to 100 N·m (73 ft. lbs.) torque..
(2) Measure the connecting rod bore with the bear- ings installed and the bolts tightened to 100 N·m (73 ft. lbs.) torque.
Measure within 20° arc from each side of the part-
ing line. Also measure 90° from parting line.
Record the smallest and largest diameter. Measure the diameter of the rod journal at the location shown (Fig. 65). Calculate the average diam- eter for each side of the journal.
Determine minimum bearing clearance by calculating the differance between the smallest connecting rod bore diameter with the bearing installed and the average diameter for each side of the crankshaft journal.
Determine the maximum bearing clearance by calcu- lating the difference between the largest connecting rod bore diameter and the average diameter with the bear- ing installed for each side of the crankshaft journal.
DESCRIPTION CONNECTING ROD BORE, BEARINGS REMOVED
CONNECTING ROD BORE, BEARINGS INSTALLED
MEASUREMENT MIN. 72.99 mm (2.874
in.)MAX. 73.01 mm (2.875
in.) MIN. 69.05 mm (2.719
in.)MAX. 69.10 mm (2.720
in.)Fig.65ConnectingRodJournalDiameterLimits
CONNECTING ROD JOURNAL DIAMETER
LIMITS CHART
DESCRIPTION
CRANKSHAFT ROD JOURNAL
DIAMETER
BEARING CLEARANCE
MEASUREMENT
Min. 68.96 mm (2.715 in.) Max. 69.01 mm (2.717 in.)
Min. 0.04 mm (.002 in.)
Max. 0.12 mm (0.005 in.)
If the crankshaft is within limits, replace the bear- ing. If the crankshaft is out of limits, grind the crankshaft to the next smaller size and use oversize rod bearings.
9 - 322
ENGINE 5.9L DIESEL
DR
truding 1.0 mm (0.039 inch) to 1.5 mm (0.059 inch) above the crankshaft (Fig. 67).
CRANKSHAFT AND GEAR DESCRIPTION
The crankshaft (Fig. 66) is a forged steel, integrally balanced unit. It is supported by seven main bear- ings, with position number six designated as the thrust journal. The crankshaft is held in place by main caps and 12 mm capscrews. The crankshaft also has internal cross drillings to supply the con- necting rods with engine oil.
Fig.67InstallingAlignmentPin
1 - ALIGNMENT PIN
WARNING: WEAR PROTECTIVE GLOVES TO PRE- VENT INJURY.
CAUTION: DO NOT heat the gear longer than 45
minutes.(3) Heat the crankshaft gear for 45 minutes at a temperature of 149°C (300°F). Do not use torch, gear failure will occur.
(4) Apply a thin coat of lubricant to the nose of the
crankshaft.
(5) Position the gear with the timing mark out and install it on the crankshaft using the alignment pin. Make sure the gear contacts the shoulder.
CRANKSHAFT MAIN BEARINGS STANDARD PROCEDURE - MAIN BEARING CLEARANCE
Inspect the main bearing bores for damage or
abnormal wear.
(1) Remove bearings and measure main bearing bore diameter after torquing main bearing cap bolts to 176 Nm (130 ft. lbs.).
(2) Install the crankshaft main bearings and mea- sure main bearing bore diameter with the main bolts tightened to 176 N·m (130 ft. lbs.) torque (Fig. 68).
Fig.66Crankshaft
REMOVAL—GEAR
(1) Remove the gear housing cover. (Refer to 9 - ENGINE/VALVE TIMING/GEAR HOUSING COVER - REMOVAL)
(2) Remove the crank gear using a heavy duty
(3) Split the gear and remove it from the crank-
puller.
shaft.
INSTALLATION - GEAR
(1) Remove all burrs and make sure the gear sur-
face on the end of the crankshaft is smooth.
(2) If removed, install a new alignment pin. Drive the pin in using a ball- peen hammer, leaving it pro-
DR CRANKSHAFT MAIN BEARINGS (Continued)
(3) Measure the diameter of the main journal at the locations shown (Fig. 69). Calculate the average diameter for each side of the journal.
Fig.68CrankshaftMainBearingBoreDiameter
1 - MAIN BEARING CAPS
MAIN BEARING BORE DIAMETER CHART
ITEM
BEARINGS INSTALLED BEARINGS REMOVED
MAIN BEARING BORE DIAMETER (MAXIMUM) 83.106 mm (3.2719 in.) Min 87.983 mm (3.4639
in.)
Max. 88.019 mm (3.4653
in.)
Fig.69CrankshaftMainJournalDiameter
ENGINE 5.9L DIESEL
9 - 323
CRANKSHAFT MAIN JOURNAL DIAMETER
CHART
ITEM
Minimum diameter Maximum diameter
Maximum out of
roundness
Maximum taper
SPECIFICATION
82.962 mm (3.2662 in.) 83.013 mm (3.2682 in.)
0.050 mm (.002 in.)
0.013 mm (.0005 in.)
Thrust distance (at No.6
Min. 0.065 mm (.003 in.)
position)
Max. 0.432 mm (.017 in.)
(4) Calculate the main bearing journal to bearing clearance. Maximum clearance is 0.119 mm (0.00475
inch). If the crankshaft journal is within limits, replace the main bearings. If not within specifica- tions, grind the crankshaft to next size and use over- size bearings.(5) Measure thrust distance at the No.6 position.
CRANKSHAFT OIL SEAL - FRONT REMOVAL
(1) Disconnect both battery negative cables. (2) Raise vehicle on hoist. (3) Partially drain engine coolant into container suitable for re-use (Refer to 7 - COOLING - STAN- DARD PROCEDURE).
(4) Lower vehicle. (5) Remove radiator upper hose. (6) Disconnect coolant recovery bottle from radia-
tor filler neck and lift bottle off of fan shroud.
(7) Disconnect windshield washer pump supply hose and electrical connections and lift washer bottle off of fan shroud.
(8) Remove the fan shroud-to-radiator mounting
bolts.
(9) Remove viscous fan/drive assembly. (Refer to 7
- COOLING/ENGINE/RADIATOR FAN - REMOVAL). (10) Remove cooling fan shroud and fan assemblyfrom the vehicle.
(11) Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(12) Remove the cooling fan support/hub from the
front of the engine.
(13) Raise the vehicle on hoist. (14) Remove the crankshaft damper and speed
indicator ring.
(15) Remove hydraulic pump. (16) Remove accessory drive belt tensioner.
ENGINE 5.9L DIESEL
9 - 324
CRANKSHAFT OIL SEAL - FRONT (Continued)DR
(17) Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar the gasket surfaces. Remove crank seal dust shield with cover.
(18) Support the cover on a flat work surface with wooden blocks (Fig. 70), and using a suitable punch and hammer, drive the old seal out of the cover from the back side of the cover to the front side (Fig. 70).
(5) Install the plastic seal pilot (provided with seal
kit) into the crankshaft seal.
Fig.71InstallingSealIntoCoverWithTool8281
1 - SEAL INSTALLER 8281
2 - DRIVER HANDLE C4171
3 - SEALFig.70RemovingSealfromCover
1 - PUNCH
