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INSTALLATION
(1) Clean cover and housing gasket mating sur- faces. Use a suitable scraper and be careful not to damage the gear housing surface. Remove any old sealer from the oil seal bore. Thoroughly clean the front seal area of the crankshaft. The seal lip and the sealing surface on the crankshaft must be free from all oil residue to prevent seal leaks.
(2) Inspect the gear housing and cover for cracks and replace if necessary. Carefully straighten any bends or imperfections in the gear cover with a ball- peen hammer on a flat surface. Inspect the crank- shaft front journal for any grooves or nicks that would affect the integrity of the new seal.
(3) Apply a bead of Mopart Stud & Bearing Mount to the outside diameter of the seal. Do not lubricate the inside diameter of the new seal.
(4) With the cover supported by wood blocks, install the seal into the rear of the cover using crank- shaft seal installer Special Tool 8281 and driver han- dle C-4171 (Fig. 71). Strike the driver handle until the installation tool bottoms out on the inside of the cover.
CAUTION: Do not distort or damage seal.
Fig.72InstallingFrontCoverwithSealPilot
1 - SEAL PILOT
(6) Apply a bead of Mopart Silicone Rubber Adhe- sive Sealant or equivalent to the gear housing cover sealing surface.
(7) Install the cover to the gear housing, aligning the seal pilot with the nose of the crankshaft (Fig. 72).
(8) Install the cover bolts and tighten to 24 N·m
(18 ft. lbs.) torque. Remove pilot tool.
(9) Install dust shield over nose of crankshaft. (10) Install the crankshaft damper and speed indi- cator ring. Torque the bolts to 40 N·m (30 ft. lbs.). Then rotate an additional 60°. Use the engine bar-
DR CRANKSHAFT OIL SEAL - FRONT (Continued)
ENGINE 5.9L DIESEL
9 - 325
ring tool to keep the engine from rotating during tightening operation.
(11) Install
the fan support/hub assembly and
torque bolts to 32 N·m (24 ft. lbs.).
(12) Install hydraulic pump. (13) Install accessory drive belt tensioner. Torque
bolt to 43 Nm (32 ft.lbs.).
(14) Install cooling fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
(15) Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(16) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(17) Connect battery negative cables. (18) Start engine and check for oil leaks.
CRANKSHAFT OIL SEAL - REAR REMOVAL
(1) Disconnect the battery negative cables. (2) Remove the transmission and transfer case (if
equipped).
(3) Remove the clutch cover and disc (if manual to 6 - CLUTCH/
(Refer
transmission equipped) CLUTCH DISC - REMOVAL).
(4) Remove the flywheel or converter drive plate. (5) Drill holes 180° apart into the seal. Be careful
not to contact the drill against the crankshaft.
(6) Install #10 sheet metal screws in the drilled holes and remove the rear seal with a slide hammer (Fig. 73).
Fig.73CrankshaftRearSealRemoval
1 - NO. 10 SCREW 2 - REAR SEAL 3 - CRANKSHAFT 4 - SLIDE HAMMER
INSTALLATION
CAUTION: The seal lip and the sealing surface on the crankshaft must be free from all oil residue to prevent seal leaks. The crankshaft and seal sur- faces must be completely dry when the seal is installed. Use a soap and water solution on outside diameter of seal to ease assembly.
(1) Clean the crankshaft journal with a suitable solvent and dry with a clean shop towel or com- pressed air. Wipe the inside bore of the crankshaft seal retainer with a clean shop towel.
journal
(2) Inspect
the crankshaft
for gouges, nicks, or other imperfections. If the seal groove in the crankshaft is excessively deep, install the new seal 1/8” deeper into the retainer bore, or obtain a crank- shaft wear sleeve that is available in the aftermar- ket.
(3) Install the seal pilot and new seal, provided in
the replacement kit, onto the crankshaft.
(4) Remove the seal pilot. (5) Install the installation tool over crankshaft. (6) Using a ball peen hammer, strike the tool at the 12, 3, 6, and 9 o’clock positions until the align- ment tool bottoms out on the retainer (Fig. 74).
Fig.74SealInstallationUsingAlignmentTooland
Hammer
1 - SEAL PILOT TOOL 2 - INSTALLATION TOOL 3 - SEAL 4 - RETAINER
(7) Install the flywheel or converter drive plate.
Tighten the bolts to 137 N·m (101 ft. lbs.) torque.
(8) Install the clutch cover and disc (if equipped) (Refer to 6 - CLUTCH/CLUTCH DISC - INSTALLA- TION).
(9) Install the transmission and transfer case (if
equipped).
(10) Lower vehicle.
ENGINE 5.9L DIESEL
9 - 326
CRANKSHAFT OIL SEAL - REAR (Continued)(11) Connect battery negative cables. (12) Check engine oil level and adjust, if necessary. (13) Start engine and check for oil leaks.
CRANKSHAFT REAR OIL SEAL RETAINER REMOVAL
DR
(2) Inspect oil pan gasket for nickes or cuts. If gas- ket is damaged, the oil pan must be removed and gasket must be replaced. Wipe oil pan gasket dry and apply light coating of RTV.
(3) Using the retainer alignment/seal installation tool provided in the seal service kit, install the align- ment tool into the retainer and install to the cylinder block (Fig. 76), using a new gasket. Tighten the six (6) mounting bolts by hand.
(1) Disconnect the battery negative cables. (2) Raise vehicle on hoist. (3) Remove the oil pan drain plug and drain the engine oil. Re-install plug and torque to 50 N·m (44
ft. lbs.) torque.(4) Remove transmission and transfer case (if
equipped) from vehicle.
(5) Remove flywheel or torque converter drive
plate.
(6) Disconnect starter cables from starter motor. (7) Remove starter motor (Refer to 8 - ELECTRI- CAL/STARTING/STARTER MOTOR - REMOVAL) and transmission adapter plate assembly.
(8) Remove four (4) oil pan rear bolts. Slide a feeler guage between the seal retainer and oil pan gasket to break the seal.
(9) Remove the six (6) retainer-to-block bolts (Fig.
75).
(Fig. 75).
(10) Remove the rear seal retainer and gasket
(11) Support the seal retainer and drive out the crankshaft seal with a hammer and suitable punch.
Fig.75CrankshaftRearSealRetainerandGasket 1 - RETAINER 2 - GASKET 3 - BOLT
INSTALLATION
(1) If using the old seal retainer, the crankshaft
seal must be replaced.
Fig.76AligningSealRetainerwithAlignment/
InstallationTool
1 - ALIGNMENT / INSTALLATION TOOL 2 - SEAL RETAINER
(4) The seal alignment tool is used to align rear cover properly. Starting with the center two bolts, tighten the retainer in a circular pattern to 10 N·m (89 in. lbs.). Remove the alignment tool.
CAUTION: The seal lip and the sealing surface on the crankshaft must be free from all oil residue to prevent seal leaks. The crankshaft and seal sur- faces must be completely dry when the seal is installed. Use a soap and water solution on outside diameter of seal to ease assembly.
(5) Make sure the provided seal pilot is installed into the new crankshaft seal. Use the alignment/in- stallation tool and press the seal onto the crankshaft (Fig. 77). Alternately drive the seal at the 12, 3, 6
and 9 o’clock positions.(6) Remove the alignment
tool and trim the retainer gasket even with the oil pan mounting sur- face (Fig. 78).
(7) Remove the seal pilot. (8) Apply a small amount of Mopart Silicone Rub-
ber Adhesive Sealant to the oil pan rail T-joints.
(9) Install the four (4) oil pan rear mounting bolts
and torque to 28 N·m (21 ft. lbs.).
(10) Install new rectangular ring seal for cam bore.
DR CRANKSHAFT REAR OIL SEAL RETAINER (Continued)
ENGINE 5.9L DIESEL
9 - 327
SOLID LIFTERS/TAPPETS REMOVAL
NOTE: This procedure requires use of Miller Tool 8502 Tappet Replacement Kit.
(1) Remove camshaft (Refer to 9 - ENGINE/EN- GINE BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) - REMOVAL).
(2) Insert the trough (provided with tool kit) the full length of the camshaft bore (Fig. 79). Make sure the cap end goes in first and the open side faces up (towards tappets).
(3) Remove only one tappet at a time. Remove rubber band from one cylinder pair and attach tappet dowel not being removed to the next cylinder pair (Fig. 80).
Fig.77InstallingSealUsingAlignmentTooland
Hammer
1 - SEAL PILOT TOOL 2 - INSTALLATION TOOL 3 - SEAL 4 - RETAINER
Fig.78TrimmingExcessGasketMaterial
1 - TROUGH
1 - GASKET
Fig.79InsertingtheTrough-Typical
(11) Install the flywheel housing and bolts. Torque
bolts to 77 N·m (57 ft. lbs.).
(12) Install the flywheel or converter drive plate.
Tighten bolts to 137 N·m (101 ft. lbs.).
(13) Install the starter motor and torque to 43 N·m (21 ft. lbs.)(Refer to 8 - ELECTRICAL/STARTING/ STARTER MOTOR - INSTALLATION).
(14) Install the transmission and transfer case (if
equipped).
(15) Lower vehicle. (16) Fill the crankcase with new engine oil. (17) Connect the battery negative cables. (18) Start engine and check for oil leaks.
Fig.80SecureDowel/TappettoAdjacentCylinder-
typical
ENGINE 5.9L DIESEL
9 - 328
SOLID LIFTERS/TAPPETS (Continued)DR
(4) Raise dowel rod (disengage from tappet) and
allow tappet to fall into trough (Fig. 81).
(5) Carefully remove trough (do not rotate) and tappet. If the tappet is not being replaced, mark it so it can be installed in its original location.
(6) Re-install
trough and repeat procedure on
remaining tappets.
INSTALLATION
(1) Insert the trough the full length of the cam- shaft bore. Again, make sure the cap end goes in first and the open side faces up (towards tappets).
(2) Lower the tappet installation tool through the
push rod hole (Fig. 83) and into the trough.
(3) Retrieve the tappet installation tool using the
hooked rod provided with the tool kit (Fig. 84).
Fig.81LiftDowelRodtoDisengagefromTappet-
typical
CLEANING
Clean tappet with a suitable solvent. Rinse in hot water and blow dry with a clean shop rag or com- pressed air.
INSPECTION
Fig.83InsertInstallationToolthroughPushRod
Hole-Typical
(1) Visually inspect the tappet the tappet socket, stem, and face for excessive wear, cracks, or obvious damage (Fig. 82).
(2) Measure the tappet stem diameter. Replace the
tappet if it falls below the minimum size (Fig. 82).
Fig.84RetrieveTappetInstallationToolthrough
CamBore-Typical
Fig.82TappetInspection
TAPPET STEM DIAMETER 15.936 mm (0.627 in.) MIN.
15.977 mm (0.629 in.) MAX.
DR SOLID LIFTERS/TAPPETS (Continued)
(4) Lubricate the tappet with clean engine oil or suitable equivalent and install the tappet to the installation tool (Fig. 85).
(5) Pull the tappet up and into position (Fig. 85). If difficulty is experienced getting the tappet to make the turn into the tappet bore, wiggle the trough while gently pulling up on the tappet.
(6) With the tappet in place, rotate the trough one half turn so the open side is down (toward crank- shaft) (Fig. 86).
(7) Remove the tappet installation tool from the
(8) Re-install a dowel rod and secure the rod with
tappet.
a rubber band.
(9) Rotate the trough one half turn and repeat the
procedure for the remaining tappets.
(10) Install the camshaft (Refer to 9 - ENGINE/ ENGINE BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) - INSTALLATION).
ENGINE 5.9L DIESEL
9 - 329
PISTON & CONNECTING ROD DESCRIPTION
PISTONS
The piston (Fig. 87) is constructed of aluminum and is gravity cast, free floating design. The piston incorporates a centrally located high swirl combus- tion bowl, and utilizes a “keystone” style top com- pression ring (Fig. 88), and a “Tapered Face” intermediate ring (Fig. 88), for superior cylinder wall scraping. Piston cooling nozzles cool the piston and pin with engine oil supplied by the crankshaft main journals. High horsepower pistons are gallery cooled and utilize J-jet piston cooling nozzles.
Fig.85InsertToolandPullTappetIntoPlace-
Typical
Fig.87Piston-Typical
Fig.86RotateTroughOneHalfTurn(180°)-Typical
Fig.88PistonRingIdentification
ENGINE 5.9L DIESEL
9 - 330
PISTON & CONNECTING ROD (Continued) CONNECTING RODSDR
The connecting rods are a split angle design (Fig. 89). They have a pressed-in-place wrist pin bushing that is lubricated by piston cooling nozzle oil spray. There are two different types of connecting rods: machined and fractured split. The main different between the two styles is the surface finish on the connecting rod split face.
Machined connecting rods can be identified by a machined surface at the connecting rod and cap split face. Machined connecting rods have numbers stamped on the rod cap and connecting rod near the parting line. The number stamped on the connecting rod must match the number stamped on the rod cap and be installed on the camshaft or intake side of the engine.
Fractured split connecting rods are first manufac- tured as a single piece and then fractured into two pieces. Fractured split connecting rods can be identi- fied by a rough and irregular surface at the connect- ing rod split face. To properly assemble the rod cap to the connecting rod, the bearing tangs on the connect- ing rod and cap must be located on the same side of the rod. The long end of the connecting rod must be assembled on the intake or camshaft side of the engine.
Measuring methods and specifications are common between fractured split and machined connecting rods.
Both fractures split and machined connecting rods and caps are machined as an assembly and are not interchangeable. If a connecting rod or cap is dam- aged, replaced. Machined and fractured split connecting rods cannot be used in the same engine.
entire assembly must be
the
STANDARD PROCEDURE - HEAD GASKET SELECTION
(1) Measure piston protrusion for all six pistons. (2) Calculate the average piston protrusion. Maxi- mum allowable protrusion is 0.516 mm (0.020 inch).
NOTE: There are two different head gaskets avail- able. One gasket is for Average piston protrusion less than 0.30 mm (0.011 inch). The other gasket is for Average piston protrusion greater than 0.30 mm (0.011 inch)
REMOVAL
(1) Disconnect the battery cables. (2) Remove the cylinder head (Refer ENGINE/CYLINDER HEAD - REMOVAL).
to 9 -
(3) Remove the oil pan and suction tube (Refer to 9
- ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(4) Remove bolts and the block stiffener.
Fig.89ConnectingRod
(5) Using Miller Tool 7471-B crankshaft barring tool, rotate the crankshaft so all of the pistons are below TDC.
(6) Before removing the piston(s) from the bore(s): (a) Remove any carbon ridge formations or deposits at the top of the bore with a dull scraper or soft wire brush.
(b) If cylinder bore wear ridges are found, use a ridge reamer to cut the ridge from the bore. DO NOT remove more metal than necessary to remove the ridge. (7) Remove the J-jet cooling nozzels, if equipped.
NOTE: If cylinders have ridges, the cylinders are oversize and will more than likely need boring.
(8) Using a hammer and steel stamp, stamp the cylinder number in the top of each piston. The front of the piston is identified by a stamping on the top of the piston. DO NOT stamp in the outside 5 mm (.197
in.) of the piston diameter. DO NOT stamp over the piston pin.(9) Mark the connecting rod and cap with the cor-
responding cylinder numbers.
(10) Remove the connecting rod bolts and rod caps. Use care so the cylinder bores and connecting rods are not damaged.
DR PISTON & CONNECTING ROD (Continued)
(11) Use a hammer handle or similar object to push the piston and connecting rod through the cyl- inder bore.
(12) Store the piston/rod assemblies in a rack.
CLEANING—PISTON AND CONNECTING ROD
CAUTION: DO NOT use bead blast to clean the pis- tons. DO NOT clean the pistons and rods in an acid tank.
PISTON
Clean the pistons and pins in a suitable solvent, rinse in hot water and blow dry with compressed air. Soaking the pistons over night will loosen most of the carbon build up. De-carbon the ring grooves with a broken piston ring and again clean the pistons in sol- vent. Rinse in hot water and blow dry with com- pressed air.
CONNECTING ROD
Clean the connecting rods in a suitable solvent, rinse in hot water and blow dry with compressed air.
INSPECTION
INSPECTION—PISTONS
Inspect the pistons for damage and excessive wear. Check top of the piston, ring grooves, skirt and pin bore. Measure the piston skirt diameter (Fig. 90). If the piston is out of limits, replace the piston.
ENGINE 5.9L DIESEL
9 - 331
The upper groove only needs to be inspected for damage. Use a new piston ring to measure the clear- ance in the intermediate ring groove (Fig. 91). Mini- mum clearance is 0.045 mm (0.0018 inch), maximum clearance is 0.095 mm (.0037 inch). If the clearance of specifications, replace the piston.
the intermediate ring exceeds
Use a new oil ring to measure the clearance in the oil groove (Fig. 91). Minimum clearance is 0.040 mm (0.0016 inch), maximum clearance is 0.085 mm (.0033 inch). If the clearance exceeds specifications, replace the piston.
Fig.91IntermediateandOilRingClearances
1 - FEELER GAUGE 2 - RING 3 - PISTON
Measure the pin bore (Fig. 92). The maximum diameter is 40.012 mm (1.5753 inch), Minimum is 40.006 mm (1.575 inch). If the bore is over limits, replace the piston.
Fig.90PistonSkirtDiameter
PISTON SKIRT DIAMETER (MIN.)
101.887 mm (4.011 in. )
Fig.92PistonPinBore
1 - PISTON 2 - PIN BORE
ENGINE 5.9L DIESEL
9 - 332
PISTON & CONNECTING ROD (Continued)Inspect the piston pin for nicks, gouges and exces- sive wear. Measure the pin diameter (Fig. 93). The minimum diameter is 39.990 mm (1.5744 inch), max- imum 40.003 mm (1.5749 inch). If the diameter is out of limits, replace the pin.
DR
(3) Compress the rings using a piston ring com- pressor tool (Fig. 95). If using a strap-type ring com- pressor, make sure the inside end of the strap does not hook on a ring gap and break the ring.
Fig.93PistonPinDiameter
1 - PISTON PIN
INSPECTION—CONNECTING ROD
Inspect the connecting rod for damage and wear. The I-Beam section of the connecting rod cannot have dents or other damage. Damage to this part can cause stress risers which will progress to breakage. Measure the connecting rod pin bore (Fig. 94). The maximum diameter is 40.042 mm (1.5765 inch), min- imum diameter is 40.019 mm (1.5756 inch). If out of limits, replace the connecting rod.
Fig.95PistonRingCompressorTool
1 - PISTON RING COMPRESSOR TOOL
(4) Bar the crankshaft so the rod journal for the piston to be installed is at BDC (Bottom Dead Cen- ter) - (Fig. 96).
Fig.96Piston/RodAssemblyatBDC
Fig.94ConnectingRodPinBore
1 - CONNECTING ROD
INSTALLATION
(1) Lubricate the cylinder bores with clean engine
oil.
(2) Generously lubricate the rings and piston
skirts with clean engine oil.
(5) Make sure the front of the piston is oriented properly according to the marking on the top of the piston and the numbers on the rod and cap are ori- ented as illustrated.
(6) Position the piston and rod assembly into the cylinder bore with the front of the piston oriented properly according to the stamping in the top of the piston. In this position the numbers on the connect- ing rod should be facing the intake or camshaft side of the engine, and the rod bolt hex heads toward the oil cooler. Use care when you install the piston and connecting rod so the cylinder bore is not damaged. If a fractured split connecting rod is being installed, the long side of the connecting rod must be installed on the intake side of the engine.
(7) Push the piston into the bore until the top of the piston is approximately 50 mm (2 inch) below the top of the block. Carefully pull the connecting rod onto the crankshaft journal.
DR PISTON & CONNECTING ROD (Continued)
ENGINE 5.9L DIESEL
9 - 333
(8) Use clean engine oil to lubricate the threads
and under the heads of the connecting rod bolts.
(9) For machined connecting rods, the number stamped on the rod cap at the parting line must match and be installed towards the intake or cam- shaft side of the engine (Fig. 97). For fractured/ split type connecting rods, the long end of the rod must be installed towards the intake side of the engine.
(a) The connecting rod split/face must
face toward the same side as the piston notch feature on the skirt. The split face will face toward the oil cooler side of the engine if properly installed.
Fig.97CorrectRodCapInstallation
(10) Install the rod cap and bolts to the connecting rod. Tighten the connecting rod bolts evenly in 3
steps.† Tighten the bolts to 30 N·m (22 ft. lbs.) torque. † Tighten the bolts to 60 N·m (44 ft. lbs.) torque. † Rotate 60° clockwise. (11) The crankshaft must rotate freely. Check for freedom of rotation as the caps are installed. If the crankshaft does not rotate freely, check the installa- tion of the rod bearing and the bearing size.(12) Measure the side clearance between the con- necting rod and the crankshaft (Fig. 98). DO NOT measure the clearance between the cap and crank- shaft.
(13) Install J-jet piston cooling nozzles if equipped. (14) Install block stiffener. Torque to 43 N·m (32 ft.
lbs.).
(15) Install the suction tube and oil pan (Refer to 9
- ENGINE/LUBRICATION/OIL PAN - INSTALLA- TION).Fig.98SideClearancebetweenConnecting
Rod/Crankshaft
1 - FEELER GAUGE ·Minimum 0.33 mm (.013 inch) ·MAX. 0.10mm (.004 inch)
(16) Install
the cylinder head onto the engine (Refer to 9 - ENGINE/CYLINDER HEAD - INSTAL- LATION).
(17) Install a new filter and fill the crankcase with
(18) Connect the battery negative cables and start
new engine oil.
engine.
PISTON RINGS STANDARD PROCEDURE - PISTON RING FITTING
(1) Determine the piston diameter and obtain the appropriate ring set. The piston rings can be identi- fied as shown in (Fig. 99).
Fig.99PistonRingIdentification
9 - 334
ENGINE 5.9L DIESEL PISTON RINGS (Continued)(2) Position each ring in the cylinder and use a piston to square it with the bore at a depth of 89.0
mm (3.5 inch) - (Fig. 100).DR
Fig.100PositionofRinginCylinderBore
1 - OIL CONTROL RING 2 - EXPANDER 3 - PISTON
Fig.101OilControlRing/ExpanderLocationin
Groove
1 - PISTON 2 - CYLINDER BORE 3 - DEPTH
(3) Use a feeler gauge to measure the piston ring
gap.
PISTON RING GAP CHART
TOP RING
0.26 - 0.36 mm
INTERMEDIATE
RING
OIL CONTROL
RING
0.85-1.15 mm
0.25-0.55 mm
(0.010 - 0.014
in.)
(0.033 - 0.045
in.)
(0.010 - 0.022
in.)
Fig.102PistonRingInstallationTool
1 - PISTON RING INSTALLATION TOOL
(4) The top surface of all of the rings are identified with the word TOP or the supplier’s MARK. Assem- ble the rings with the word TOP or the supplier’s MARK up.
(5) Position the oil ring expander in the oil control
ring groove (bottom groove).
(6) Install the oil control ring with the end gap
OPPOSITE the ends on the expander (Fig. 101).
(7) Install the intermediate piston ring in the sec-
(8) Install the top piston ring in the top groove
ond groove.
(Fig. 102).
(9) Position the rings as shown in (Fig. 103).
Fig.103PistonRingOrientation
1 - TOP RING 2 - INTERMEDIATE RING 3 - OIL CONTROL RING
DR
ENGINE 5.9L DIESEL
9 - 335
VIBRATION DAMPER REMOVAL
(1) Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(2) Remove the four (4) damper to crankshaft bolts
and remove damper and speed indicator ring.
INSPECTION
(1) Inspect the damper hub for cracks and replace
if any are found.
(2) Inspect the index lines on the damper hub and the inertia member (Fig. 104). If the lines are more than 1.59 mm (1/16 in.) out of alignment, replace the damper.
(3) Inspect the rubber member for deterioration or
missing segments (Fig. 105).
INSTALLATION
(1) Install speed indicator ring.
NOTE: The speed indicator ring is located over a dowel pin.
the
(2) Install
crankshaft damper and bolts. Tighten bolts to 40 N·m (30 ft. lbs.) torque, plus an additional 60°.
NOTE: The damper must be installed so the hole is located over the dowel pin.
(3) Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
FRONT MOUNT REMOVAL
(1) Disconnect the battery negative cables. (2) Remove the viscous fan/drive assembly (Refer - COOLING/ENGINE/RADIATOR FAN -
to REMOVAL).
(3) Raise vehicle on hoist. (4) Install engine support fixture tool# 8534 and
steel bracket tool # 8534A
(5) Loosen the thru-bolt and nut. (6) Lift the engine SLIGHTLY and remove the
insulator to block bolts (Fig. 107) (Fig. 106). (7) Remove the insulator from the vehicle.
INSTALLATION
(1) With engine raised SLIGHTLY, position the insualtor to the mount (Fig. 108) (Fig. 109). Install the bolts and torque to specification.
(2) (3) Lower the engine using tool # 8534, while guid- ing the mount and thru-bolt into the frame mounted support cushion brackets.
(4) Install the thru-bolt nut and tighten the nut to
88 N·m (65 ft. lbs.) torque.
(5) Remove the engine support fixture tool #8534. (6) Lower the vehicle. (7) Install the viscous fan/drive assembly (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTAL- LATION).
(8) Connect the battery negative cables.
Fig.104InspectIndexLinesforAlignment
1 - INDEX LINES 2 - HUB 3 - INERTIA MEMBER
Fig.105InspectDamperRubberMember
ENGINE 5.9L DIESEL
9 - 336
FRONT MOUNT (Continued)DR
Fig.106RHInsulator
Fig.108LHInsulator
1 - Mount 2 - Insulator 3 - Bolt
1 - Bolt 2 - Insulator 3 - Mount
Fig.107LHInsulator
Fig.109RHInsulator
1 - Bolt 2 - Insulator 3 - Mount
1 - Mount 2 - Insulator 3 - Bolt
DR
REAR MOUNT REMOVAL
(1) Raise the vehicle on a hoist. (2) Position a transmission jack in place. (3) Remove support cushion stud nuts (Fig. 110). (4) Raise SLIGHTLY.
transmission
rear
and
of
engine
(5) Remove the bolts holding the support cushion to the transmission support bracket. Remove the sup- port cushion.
(6) If necessary, remove the bolts holding the
transmission support bracket to the transmission.
INSTALLATION
(1) If removed, position the transmission support bracket to the transmission. Install new attaching bolts and tighten to 102 N·m (75 ft. lbs.) torque.
(2) Position support cushion to transmission sup- port bracket. Install stud nuts and tighten to 47 N·m (35 ft. lbs.) torque.
(3) Using the transmission jack, lower the trans- mission and support cushion onto the crossmember (Fig. 110).
(4) Install the support cushion bolts and tighten to
47 N·m (35 ft. lbs.) torque.
(5) Remove the transmission jack. (6) Lower the vehicle.
ENGINE 5.9L DIESEL
9 - 337
LUBRICATION DESCRIPTION
NOTE: Refer to (Fig. 111) and (Fig. 112) for circuit illustrations.
A gear driven gerotor type oil pump is mounted behind the front gear cover in the lower right portion on the engine.
OPERATION
A gerotor style oil pump draws oil from the crank- case through the suction tube and delivers it through the block where it enters the oil cooler cover and pressure regulator valve. When oil pressure exceeds 517 kPa (75 PSI), the valve opens exposing the dump port, which routes excess oil back to the oil pump.
At the same time, oil is directed to a cast in pas- sage in the oil cooler cover, leading to the oil cooler element. As the oil travels through the element plates, it is cooled by engine coolant traveling past the outside of the plates. It is then routed to the oil filter head and through a full flow oil filter. If a plugged filter is encountered, the filter by-pass valve opens, allowing unfiltered oil to lubricate the engine. This condition can be avoided by frequent oil and fil- ter changes, per the maintenance schedules found in
Fig.110EngineRearSupportCushionAssembly
9 - 338
ENGINE 5.9L DIESEL LUBRICATION (Continued)the owners manual. The by-pass valve is calibrated to open when it sees a pressure drop of more than 345 kPa (50 psi) across the oil filter.
The oil filter head then divides the oil between the engine and the turbocharger. The turbocharger receives filtered, cooled and pressurized oil through a supply line from the filter head. The oil lubricates the turbocharger and returns to the pan by way of a drain tube connecting the bottom of the turbocharger to a pressed in tube in the cylinder block.
Oil is then carried across the block to an angle drilling which intersects the main oil rifle. The main oil rifle runs the length of the block and delivers oil to the crankshaft main journals and valve train. Oil travels to the crankshaft through a series of transfer drillings (one for each main bearing) and lubricates a groove in the main bearing upper shell. From there another drilling feeds the camshaft main journals. The saddle jet piston cooling nozzles are also sup- plied by the main bearing upper shell. J-jet piston cooling nozzles are supplied by a separate oil rifle. Plugs are used in place of saddle jets when J-jets are used. J-jet hole locations are plugged when saddle jet cooling nozzles are used. Crankshaft internal cross- drillings supply oil to the connecting rod journals.
Another series of transfer drillings intersecting the main oil rifle supply the valve train components. Oil travels up the drilling, through a hole in the head gasket, and through a drilling in the cylinder head (one per cylinder), where it enters the rocker arm pedestal and is divided between the intake and exhaust rocker arm. Oil travels up and around the
DR
rocker arm mounting bolt, and lubricates the rocker shaft by cross drillings that intersect the mounting bolt hole. Grooves at both ends of the rocker shaft supply oil through the rocker arm where the oil trav- els to the push rod and socket balls (Fig. 111) and (Fig. 112).
DIAGNOSIS AND TESTING—ENGINE OIL PRESSURE
(1) Remove the 1/8 npt plug from the top of the oil
filter housing.
(2) Install Oil Pressure Line and Gauge Tool
C-3292 with a suitable adapter.
(3) Start engine and warm to operating tempera-
ture.
(4) Record engine oil pressure and compare with
engine oil pressure chart.
CAUTION: If engine oil pressure is zero at idle, DO NOT RUN THE ENGINE.
Engine Oil Pressure (MIN)
At Idle
At 2500 rpm
68.9 kPa (10 psi) 206.9 kPa (30 psi)
If minimum engine oil pressure is below these ranges, (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING).
(5) Remove oil pressure gauge and install the 1/8
npt plug.
DR LUBRICATION (Continued)
ENGINE 5.9L DIESEL
9 - 339
1 - TO FILTER 2 - FROM FILTER 3 - TO MAIN OIL RIFLE 4 - CLOSED 5 - OPEN 6 - TO COOLER
Fig.111LubricationSystemCirculation
7 - FROM PUMP 8 - CLOSED 9 - OPEN 10 - OIL DRAINS BACK TO THE PUMP 11 - OIL DRAIN 12 - OIL SUPPLY
9 - 340
ENGINE 5.9L DIESEL LUBRICATION (Continued)DR
Fig.112LubricationSystemCirculation—Cont’d
DR OIL (Continued)
1 - ROCKER ARM 2 - ROCKER SHAFT 3 - PEDESTAL 4 - FROM MAIN OIL RIFLE 5 - TO VALVE TRAIN 6 - MAIN OIL RIFLE 7 - FROM MAIN OIL RIFLE
OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL LEVEL
ENGINE 5.9L DIESEL
9 - 341
8 - TO CAMSHAFT 9 - TO PISTON COOLING NOZZLE 10 - FROM OIL COOLER 11 - CRANKSHAFT MAIN JOURNAL 12 - ROD JOURNAL 13 - TO ROD BEARING 14 - MAIN OIL RIFLE
STANDARD PROCEDURE - ENGINE OIL SERVICE
WARNING: HOT OIL CAN CAUSE PERSONAL INJURY.
CAUTION: Do not overfill crankcase with engine oil, oil foaming and oil pressure loss can result.
NOTE: Change engine oil and filter at specified in the owner’s manual.
intervals
To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable oil level is in the SAFE RANGE on the engine oil dipstick (Fig. 113).
Unless the engine has exhibited loss of oil pres- sure, run the engine for about five minutes before checking oil level. Checking engine oil level of a cold engine is not accurate.
Fig.113OilLevelIndicator(Dipstick)
1 - ADD OIL MARK 2 - O-RING 3 - SAFE RANGE
(1) Position vehicle on level surface. (2) With engine OFF, allow approximately ten min- utes for oil to settle to bottom of crankcase, remove engine oil dipstick.
(3) Wipe dipstick clean. (4) Replace dipstick and verify it is seated in the
tube.
(5) Remove dipstick, with handle held above the
tip, take oil level reading.
(6) Add oil only if level is below the SAFE RANGE
area on the dipstick.
(7) Replace dipstick
(1) Operate the engine until the water tempera-
ture reaches 60°C (140°F). Shut the engine off.
(2) Use a container that can hold at least 14 liters (15 quarts) to hold the used oil. Remove the oil drain plug and drain the used engine oil into the container. (3) Always check the condition of the used oil. This can give you an indication of engine problems that might exist.
† Thin, black oil indicates fuel dilution. † Milky discoloration indicates coolant dilution. (4) Clean the area around the oil
filter head. Remove the filter (Refer to 9 - ENGINE/LUBRICA- TION/OIL FILTER - REMOVAL).
(5) Install new oil filter (Refer to 9 - ENGINE/LU-
BRICATION/OIL FILTER - INSTALLATION).
(6) Clean the drain plug and the sealing surface of the pan. Check the condition of the threads and seal- ing surface on the oil pan and drain plug.
(7) Install the drain plug. Tighten the plug to 50
N·m (37 ft. lbs.) torque.
(8) Use only High-Quality Multi-Viscosity lubricat- ing oil in the Cummins Turbo Diesel engine. Choose the correct oil for the operating conditions (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION).
(9) Fill the engine with the correct grade of new oil (Refer to LUBRICATION & MAINTENANCE/FLUID CAPACITIES - SPECIFICATIONS).
(10) Start the engine and operate it at idle for sev- eral minutes. Check for leaks at the filter and drain plug.
(11) Stop engine. Wait several minutes to allow the oil to drain back to the pan and check the level again.
USED ENGINE OIL DISPOSAL
Care should be exercised when disposing of used engine oil after it has been drained from a vehicle’s engine.
9 - 342
ENGINE 5.9L DIESEL
OIL COOLER & LINES
CLEANING
CLEANING AND INSPECTION
Clean the sealing surfaces. Apply 483 kPa (70 psi) air pressure to the element to check for leaks. If the element leaks, replace the element.
OIL FILTER REMOVAL
(1) Clean the area around the oil
filter head. Remove the filter from below using a cap-style filter wrench.
(2) Clean the gasket surface of the filter head. The filter canister O-Ring seal can stick on the filter head. Make sure it is removed.
INSTALLATION
(1) Fill the oil filter element with clean oil before installation. Use the same type oil that will be used in the engine.
(2) Apply a light film of lubricating oil to the seal-
ing surface before installing the filter.
CAUTION: Mechanical over-tightening may distort the threads or damage the filter element seal.
(3) Install the filter until it contacts the sealing surface of the oil filter adapter. Tighten filter an additional 1⁄2 turn.
OIL PAN REMOVAL
(1) Disconnect the battery negative cables. (2) Install engine support fixture # 8534. (3) Raise vehicle on hoist. (4) Disconnect starter cables from starter motor. (5) Remove starter motor (Refer to 8 - ELECTRI- CAL/STARTING/STARTER MOTOR - REMOVAL) and transmission adapter plate assembly.
(6) Remove transmission and transfer case (if
equipped).
(7) Remove flywheel or flexplate. (8) Remove the transmission adapter plate.
WARNING: HOT OIL CAN CAUSE PERSONAL INJURY.
(9) Drain the engine oil (Refer to 9 - ENGINE/LU-
BRICATION/OIL - STANDARD PROCEDURE).
DR
(10) Install the oil pan drain plug if sealing sur- face is not damaged and tighten to 50 N·m (57 ft. lbs.) torque.
(11) Remove oil pan bolts, break the pan to block seal, and lower pan slightly and remove oil suction tube fasteners.
(12) Remove oil pan and suction tube.
CLEANING
Remove all gasket material from the oil pan and cylinder block sealing surfaces. Extra effort may be required around T-joint areas. Clean oil pan and flush suction tube with a suitable solvent.
INSPECTION
Inspect the oil pan, suction tube, and tube braces for cracks and damage. Replace any defective compo- nent. Inspect the oil drain plug and drain hole threads. the oil pan sealing surface for straightness. Repair any minor imperfections with a ball-peen hammer. Do not attempt to repair an oil pan by welding.
Inspect
INSTALLATION
(1) Fill the T-joint between the pan rail/gear hous- ing and pan rail/rear seal retainer with sealant. Use Mopart Silicone Rubber Adhesive Sealant or equiva- lent.
(2) Place suction tube in oil pan and guide them into place. Using a new tube to block gasket, install and tighten the suction tube bolts by hand. Starting with the oil pump inlet bolts, tighten the bolts to 24
N·m (18 ft. lbs.) torque. Tighten the remaining tube brace bolts to 43 N·m (32 ft. lbs.) torque.(3) Starting in the center and working outward, lbs.)
tighten the oil pan bolts to 28 N·m (21 ft. torque.
(4) Install the flywheel housing assembly with the starter motor attached and tighten bolts to 77 N·m (57 ft. lbs.) torque.
(5) Connect starter motor cables. (6) Install the flywheel or flexplate. Torque to 137
N·m (101 ft. lbs.).
equipped).
(7) Install
transmission and transfer
case (if
(8) Lower vehicle. (9) Remove the engine support fixture # 8534. (10) Install battery negative cables. (11) Fill the crankcase with new engine oil. (12) Start engine and check for leaks. Stop engine,
check oil level, and adjust, if necessary.
DR
ENGINE 5.9L DIESEL
9 - 343
OIL PRESSURE RELIEF VALVE REMOVAL
(1) Disconnect the battery negative cables. (2) Remove the threaded plug, spring and plunger (Fig. 114). Insert a finger or a seal pick to lift the plunger from the bore.
NOTE: If the plunger is stuck in the bore, it will be necessary to remove the filter head.
Fig.115OilPressureRegulatorSpringCheck
OIL PRESSURE SENSOR/ SWITCH REMOVAL
(1) Disconnect the battery negative cables. (2) Disconnect the oil pressure switch connector. (3) Using a suitable socket, remove the oil pres-
sure switch from the block (counter-clockwise).
INSTALLATION
(1) If the switch is not being replaced, replace and
lubricate the o-ring.
(2) Install the oil pressure switch and tighten to
18 N·m (159 in. lbs.) torque.
(3) Connect oil pressure switch connector. (4) Connect the battery negative cables. (5) Start engine and check for oil
leaks at the
switch.
OIL PUMP REMOVAL
(1) Disconnect the battery negative cables. (2) Remove fan/drive assembly (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL).
(3) Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(4) Remove the fan support/hub assembly. (Refer (5) Remove crankshaft damper
to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL) and speed indicator ring.
(6) Remove hydraulic pump. (7) Remove accessory drive belt tensioner. (8) Remove the gear housing cover (Refer to 9 - ENGINE/VALVE TIMING/GEAR HOUSING COVER - REMOVAL).
Fig.114OilPressureRegulator
1 - OIL FILTER 2 - PLUG 3 - GASKET 4 - SPRING 5 - VALVE
CLEANING
(1) Clean the regulator spring and plunger with a suitable solvent and blow dry with compressed air. If the plunger bore requires cleaning, it is necessary to remove the oil filter head to avoid getting debris into the engine.
INSPECTION
Inspect the plunger and plunger bore for cracks and excessive wear. Polished surfaces are acceptable. Verify that the plunger moves freely in the bore.
Check the spring for height and load limitations (Fig. 115). Replace the spring if out of limits shown in the figure.
INSTALLATION
(1) Install the plunger, spring, and plug as shown in (Fig. 114). Tighten the plug to 80 N·m (60 ft. lbs.) torque.
(2) Connect the battery negative cables. (3) Start the engine and verify that it has oil pres-
sure.
ENGINE 5.9L DIESEL
9 - 344
OIL PUMP (Continued)(9) Remove the four mounting bolts and pull the oil pump from the bore in the cylinder block (Fig. 116).
DR
Fig.116OilPumpRemoval/Installation
1 - OIL PUMP 2 - BOLT (4)
CLEANING
Clean all parts in solvent and dry with compressed air. Clean the old sealer residue from the back of the gear housing cover and front of the gear housing.
INSPECTION
lows:
Disassemble and inspect the oil pump as fol-
(1) Visually inspect the lube pump gears for chips,
cracks or excessive wear.
(2) Remove the back plate (Fig. 117). (3) Mark TOP on the gerotor planetary using a felt
tip pen (Fig. 117).
(4) Remove
the gerotor planetary (Fig. 117). Inspect for excessive wear or damage. Inspect the pump housing and gerotor drive for damaged and excessive wear.
(5) Install the gerotor planetary in the original
position.
(6) Measure the tip clearance (Fig. 118). Maximum clearance is 0.1778 mm (0.007 inch). If the oil pump is out of limits, replace the pump.
(7) Measure the clearance of the gerotor drive/ gerotor planetary to port plate (Fig. 119). Maximum clearance is 0.127 mm (0.005 inch). If the oil pump is out of limits, replace the pump.
(8) Measure the clearance of the gerotor planetary to the body bore (Fig. 120). Maximum clearance is 0.381 mm (0.015 inch). If the oil pump is out of lim- its, replace the pump.
(9) Measure the gears backlash (Fig. 121). The limits of a used pump is 0.15- 0.25 mm (0.006-0.010
Fig.117GerotorPlanetaryandGerotor
1 - OIL PUMP BACK PLATE 2 - GEROTOR 3 - GEROTOR PLANETARY
Fig.118MeasuringTipClearance
1 - FEELER GAUGE
Fig.119MeasuringGerotortoPortPlateClearance 1 - PORT PLATE 2 - GEROTOR
inch). If the backlash is out of limits, replace the oil pump.
(10) Install the back plate.
INSTALLATION
(1) Lubricate the pump with clean engine oil. Fill- ing the pump with clean engine oil during installa- tion will help to prime the pump at engine start up.
DR OIL PUMP (Continued)
ENGINE 5.9L DIESEL
9 - 345
(3) The back plate on the pump seats against the bottom of the bore in the cylinder block. When the pump is correctly installed, the flange on the pump will not touch the cylinder block.
(4) Measure the idler gear to pump drive gear backlash and the idler gear to crankshaft gear back- lash (Fig. 123). The backlash should be 0.15- 0.25
mm (0.006-0.010 inch). If the backlash is out of lim- its, replace the oil pump.(5) If the adjoining gear moves when you measure
the backlash, the reading will be incorrect.
Fig.123IdlerGeartoPumpDriveGearand
CrankshaftGearBacklash
(6) Apply a bead of Mopart Silicone Rubber Adhe- sive Sealant or equivalent to the gear housing cover sealing surface.
(7) Install the gear housing cover (Refer to 9 - ENGINE/VALVE TIMING/GEAR HOUSING COVER - INSTALLATION).
(8) Install
the vibration damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION) and speed indicator ring.
(9) Install
the fan support/hub assembly and
torque bolts to 32 N·m (24 ft. lbs.).
(10) Install hydraulic pump. (11) Install accessory drive belt tensioner. Torque
bolt to 43 N·m (32 ft. lbs.).
(12) Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(13) Install the cooling fan (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION).
(14) Connect battery negative cables. (15) Start engine and check for oil leaks.
INTAKE MANIFOLD REMOVAL
(1) Disconnect the battery negative cables. (2) Remove the charge air cooler outlet tube from
the air inlet housing (Fig. 124).
(3) Remove the engine oil dipstick tube mounting
bolt (Fig. 124).
Fig.120MeasuringGerotorPlanetarytoBodyBore
Clearance
1 - BODY BORE 2 - GEROTOR PLANETARY
Fig.121MeasureGearBacklash
1 - OIL PUMP DRIVE GEAR 2 - IDLER GEAR 3 - BACKLASH 4 - BACKLASH
(2) Install the pump (Fig. 116). Verify the idler gear pin is installed in the locating bore in the cylin- der block. Tighten the oil pump mounting bolts in two steps, in the sequence shown in (Fig. 122).
† Step 1—Tighten to 8 N·m (71 in. lbs.) torque. † Step 2—Tighten to 24 N·m (18 ft. lbs.) torque.
Fig.122OilPumpMountingBoltTorqueSequence
ENGINE 5.9L DIESEL
9 - 346
INTAKE MANIFOLD (Continued)DR
(4) Remove dipstick support at fuel filter housing.
Position dipstick tube to the side.
(5) Disconnect the air grid heater power cables at
the cable mounting studs.
(6) Disconnect
the ground strap at
the intake
cover.
(7) Remove the engine wiring harness connections
at the air inlet housing elbow.
(8) Remove the four (4) air inlet housing mounting bolts and remove the housing from top of the heater elements.
(9) Remove the intake air grid heater from the
manifold (Fig. 125).
Fig.125IntakeAirGridHeater
1 - INTAKE AIR GRID HEATER 2 - GASKET
(15) Clean the intake manifold cover and cylinder
head sealing surface.
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
able solvent.
Clean cylinder block gasket surfaces using a suit-
The plenum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks. Inspect mating surfaces of manifold for flatness
with a straightedge.
INSTALLATION
(1) Using a new gasket, install the intake manifold
cover.
(2) Install the cover-to-cylinder head bolts that do not hold down the fuel rail. Tighten the bolts to 24
N·m (18 ft. lbs.) torque.(3) Install the high pressure rail and fuel
lines (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/ FUEL LINES - INSTALLATION).
(4) Using two (2) new gaskets, install the intake air grid heater and air inlet housing. Position the ground cable and install and tighten the bolts to 24
N·m (18 ft. lbs.) torque.Fig.124ChargeAirCoolerAirTube
1 - FRONT WIRING CLIP 2 - GROUND CABLE 3 - TUBE BOLT 4 - ENGINE OIL DIPSTICK TUBE 5 - CLAMPS 6 - AIR TUBE (INT. MAN.-TO-INTERCOOLER) 7 - RUBBER HOSE 8 - AIR INTAKE HOUSING 9 - CABLE BRACKET HOUSING
(10) Remove the high pressure fuel lines and fuel rail (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/ FUEL LINES - REMOVAL).
(11) Remove APPS bracket from cylinder head to
gain access to front intake manifold cover bolts.
(12) Disconnect manifold air temperature/pressure
sensor connector.
to-cylinder head bolts.
(13) Remove the remaining intake manifold cover-
(14) Remove the intake manifold cover and gasket. Keep the gasket material and any other material out of the air intake.
DR INTAKE MANIFOLD (Continued)
ENGINE 5.9L DIESEL
9 - 347
(5) Connect the manifold air temperature/pressure
sensor connector.
(6) Install and tighten the air intake heater power
supply nuts to 14 N·m (120 in. lbs.) torque.
(7) Install the APPS bracket. Torque fasteners to
43 N·m (32ft lbs.) torque.
(8) Install oil dipstick tube support at fuel filter
housing.
ing bolt.
(9) Install the engine oil dipstick tube and mount-
(10) Position the charge air cooler outlet tube onto the air inlet housing. Tighten the clamps to 8 N·m (72 in. lbs.) torque.
(11) Attach the engine wire harness to the air inlet
housing at two locations.
(12) Prime the fuel system. Refer to the fuel prim-
ing procedure in Group 14, Fuel System.
(13) Connect the battery negative cables.
EXHAUST MANIFOLD REMOVAL
(1) Disconnect the battery negative cables. (2) Raise vehicle on hoist. (3) Disconnect the exhaust pipe from the turbo-
charger elbow.
(4) Lower vehicle. (5) Disconnect the turbocharger air inlet hose. (6) Remove air cleaner assembly. (7) Disconnect the turbocharger oil supply line and
the oil drain tube from the turbocharger.
(8) Disconnect the charge air cooler inlet pipe from
(9) Remove the turbocharger and gasket from the
the turbocharger.
exhaust manifold.
(10) Remove the cab heater return pipe nuts from the exhaust manifold stud. Position the tube out of the way.
(11) Remove heat shield. (12) Remove exhaust manifold bolt lockplates. (13) Remove the exhaust manifold-to-cylinder head
bolts and spacers (Fig. 126).
(14) Remove the exhaust manifold and gaskets
(Fig. 126).
CLEANING
Clean the cylinder head and exhaust manifold seal- ing surfaces with a suitable scraper. Use a Scotch- Brite™ pad or equivalent.
INSPECTION
Inspect the exhaust manifold for cracks. Measure the exhaust manifold for flatness. Place a ruler over all of the exhaust ports and insert a feeler gauge
Fig.126ExhaustManifoldandGaskets
1 - RETAINING STRAP 2 - BOLT (7) 3 - SPACER 4 - MANIFOLD, EXHAUST 5 - GASKET 6 - BOLT (5)
between the port flange and the ruler. Maximum deviation from flat is 0.20 mm (.008 inch).
INSTALLATION
(1) Using new gaskets, install the exhaust mani- fold and gaskets. Install the bolts and spacers and tighten the bolts in the sequence shown in to 43 N·m (32 ft. lbs.) torque.
(2) Retorque the four center bolts. (3) Install heat shield and torque bolts to 24 Nm
(18 ft. lbs.).
(4) Install cab heater tube. (5) Install exhaust manifold bolt retention straps. (6) Install the cab heater return hose to the man- ifold bolt stud. Tighten the nut to 24 N·m (18 ft. lbs.) torque.
(7) Install the turbocharger and a new gasket. Apply anti-seize to the studs and then tighten the turbocharger mounting nuts to 43 N·m (32 ft. lbs.) torque.
ENGINE 5.9L DIESEL
9 - 348
EXHAUST MANIFOLD (Continued)DR
(8) Install the oil drain tube and a new gasket to the turbocharger. Tighten the drain tube bolts to 24
N·m (18 ft. lbs.) torque.(9) Pre-lube the turbocharger. Pour 50 to 60 cc (2 to 3 oz.) clean engine oil in the oil supply line fit- ting on the turbo. Rotate the turbocharger impeller by hand to distrubute the oil thoroughly.
(10) Install and tighten the oil supply line fitting
nut to 24 N·m (18 ft. lbs.) torque.
(11) Position the charge air cooler inlet pipe to the turbocharger. With the clamp in position, tighten the clamp nut to 8 N·m (72 in. lbs.) torque.
(12) Position the air inlet hose to the turbocharger.
Tighten the clamp to 8 N·m (72 in. lbs.) torque.
(13) Raise vehicle on hoist. (14) Connect the exhaust pipe to the turbocharger and tighten the bolts to 34 N·m (25 ft. lbs.) torque.
(15) Lower the vehicle. (16) Connect the battery negative cables. (17) Start the engine to check for leaks.
VALVE TIMING STANDARD PROCEDURE - TIMING VERIFICATION
(1) Remove the cylinder head cover(Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(2) Remove fuel
injector from cylinder number 1(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/ FUEL INJECTOR - REMOVAL).
(3) Using Special Tool 7471B rotate the engine until the TDC mark on the damper is at 12 o’clock. (4) Using a 8 in.x 1/4 in. dowel rod inserted into cylinder number 1, rock the crankshaft back and forth to verify piston number 1 is at TDC.
(5) With cylinder number still at TDC, inspect the keyway on the crankshaft gear for proper alignment (12 o’clock position).
(6) If the keyway is not at 12 o’clock position
replace the crankshaft gear assembly.
(7) If the keyway is at 12 o’clock position, remove front gear cover and verify timing mark alignment between the camshaft gear and crankshaft gear, if not aligned inspect keyway on camshaft gear.
(8) Inspect keyway on camshaft gear for proper alignment with the key in the camshaft, if alignment is off replace the camshaft/gear assembly.
(9) If timing marks alignment is off and no dam- age is found at either the crankshaft or camshaft gear keyways, realign timing marks as necessary.
GEAR HOUSING REMOVAL
(1) Disconnect the 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 hose from radiator 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 lower fan shroud fasteners. Disconnect
fan drive wire harness.
(9) Remove
the upper
fan shroud-to-radiator
mounting bolts.
(10) Remove viscous fan/drive assembly (Refer to 7
- COOLING/ENGINE/RADIATOR FAN - REMOVAL). (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 (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL) and speed indicator ring.
(15) Lower the vehicle. (16) Remove the hydraulic pump. (17) Remove the accessory drive belt tensioner. (18) Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar the gasket surfaces.
(19) Remove the fuel injection pump (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC- TION PUMP - REMOVAL).
(20) Disconnect the camshaft position sensor con-
nector.
(21) Disconnect and remove engine speed sensor. (22) Remove the camshaft (Refer to 9 - ENGINE/ ENGINE BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) - REMOVAL).
(23) Remove the six front oil pan fasteners. (24) Remove the gear housing fasteners.
NOTE: Use care when removing the gear housing, to avoid damage to the oil pan gasket, as the gas- ket will be reused if it is not damaged.
(25) Slide a feeler gauge between the gear housing
and oil pan gasket, to break the gasket seal. (26) Remove the gear housing and gasket.
DR GEAR HOUSING (Continued)
(27) Clean the gasket material from the cylinder
block and gear housing.
INSTALLATION
(1) Inspect oil pan gasket. If torn, gasket must be
replaced.
(2) Install a new gasket and the gear housing. Torque bolts to 24 N·m (18 ft. lbs.). Follow torque sequence.
(3) If a new housing is installed, the camshaft position sensor, and engine speed sensor must be transferred to the new housing.
(4) Connect the camshaft position sensor connec-
tor.
(5) Install and connect engine speed sensor. (6) Install the injection pump (Refer to 14 - FUEL INJECTION
DELIVERY/FUEL
SYSTEM/FUEL PUMP - INSTALLATION).
(7) Install the camshaft (Refer to 9 - ENGINE/EN- GINE BLOCK/CAMSHAFT & BEARINGS (IN BLOCK) - INSTALLATION). Align the crankshaft and camshaft gear marks as shown in.
(8) Install a new front crankshaft seal
into the
gear cover.
(9) Apply a bead of Mopart Silicone Rubber Adhe- sive Sealant or equivalent to the gear housing cover. Be sure to surround all through holes.
(10) Using the seal pilot to align the cover, install the bolts.
the cover to the housing and install Tighten the bolts to 24 N·m (18 ft. lbs.) torque.
(11) Remove the seal pilot. Install front seal dust
shield.
(12) Raise the vehicle. (13) Trim any excess gear housing gasket to make
it flush with the oil pan rail.
(14) Install the crankshaft damper and speed indi- cator ring (Refer to 9 - ENGINE/ENGINE BLOCK/ VIBRATION DAMPER - INSTALLATION). Torque bolts to 40 Nm (30 ft. lbs.), plus an additional 60°.
(15) Lower vehicle. (16) Install
the fan support/hub assembly and
tighten bolts to 32 N·m (24 ft. lbs.) torque.
(17) Install the hydraulic pump. (18) Install
the accessory drive belt Torque bolt to 43 N·m (32 ft. lbs.) torque.
tensioner.
(19) Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(20) Install
the upper cooling fan and shroud together (Refer to 7 - COOLING/ENGINE/RADIA- TOR FAN - INSTALLATION).
ENGINE 5.9L DIESEL
9 - 349
(21) Install
lower shroud and connect fan drive
harness connector.
(22) Install the windshield washer reservoir to the fan shroud and connect the washer pump supply hose and electrical connection.
(23) Install the coolant recovery bottle to the fan shroud and connect the hose to the radiator filler neck.
(24) Install the radiator upper hose and clamps. (25) Add engine oil. (26) Add coolant (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(27) Connect the battery cables. (28) Start engine and inspect for leaks.
GEAR HOUSING COVER 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 hose from radiator 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 viscous fan/drive assembly (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL). (9) Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(10) Remove the cooling fan support/hub from the
front of the engine.
(11) Raise the vehicle on hoist. (12) Remove power steering pump. (13) Remove accessory drive belt tensioner. (14) Remove the crankshaft damper and speed to 9 - ENGINE/ENGINE
indicator BLOCK/VIBRATION DAMPER - REMOVAL).
ring (Refer
(15) Lower the vehicle. (16) Remove the gear cover-to-housing bolts and gently pry the cover away from the housing, taking care not to mar the gasket surfaces.
ENGINE 5.9L DIESEL
9 - 350
GEAR HOUSING COVER (Continued) INSTALLATION(1) Install a new front crankshaft oil seal. (2) Obtain a seal pilot/installation tool
from a crankshaft front seal service kit and install the pilot into the seal.
(3) Apply a bead of Mopart Silicone Rubber Adhe- sive Sealant or equivalent to the gear housing cover. Be sure to surround all through holes.
(4) Using the seal pilot to align the cover (Fig. 127), install the cover to the housing and install the bolts. Tighten the bolts to 24 N·m (18 ft. lbs.) torque.
Fig.127InstallingCoverwithSealPilot
1 - SEAL PILOT
DR
(5) Remove the seal pilot. Install front seal dust
shield.
(6) Raise the vehicle. (7) Install the speed indicator ring and the crank- to 9 - ENGINE/ENGINE
shaft damper BLOCK/VIBRATION DAMPER - INSTALLATION).
(Refer
(8) Lower vehicle. (9) Install the fan support/hub assy, and tighten
bolts to 32 N·m (24 ft. lbs.) torque. (10) Install power steering pump. (11) Install accessory drive belt tensioner. Torque
bolt to 43 N·m (32 ft. lbs.) torque.
(12) Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(13) Install the cooling fan and shroud together (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).
(14) Install the windshield washer reservoir to the fan shroud and connect the washer pump supply hose and electrical connection.
(15) Install the coolant recovery bottle to the fan shroud and connect the hose to the radiator filler neck.
(16) Install the radiator upper hose and clamps.
