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repair/replace seized component. 5. Refer to (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
1. Check for spark. (Refer to 8 - ELECTRICAL/IGNITION CONTROL - DESCRIPTION)
2. Perform fuel pressure test, and if necessary, inspect fuel injector(s) and driver circuits. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP - DIAGNOSIS AND TESTING). 3. Perform cylinder compression pressure test. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING).
1. Install new distributor rotor 2. Remove and repair distributor (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ DISTRIBUTOR - REMOVAL). 3. Clean plugs and set gap. (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ SPARK PLUG - CLEANING). 4. Clean system and replace fuel filter 5. Install new fuel pump 6. Correct valve timing 7. Install new cylinder head gasket 8. Test cylinder compression (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING). 9. Install/Reface valves as necessary 10. Install new parts as necessary 11. Replace any cracked or shorted cables
DR ENGINE - 5.9L (Continued)
ENGINE - 5.9L
9 - 227
CONDITION
POSSIBLE CAUSES
CORRECTION
12. Faulty ignition coil
ENGINE STALLS OR ROUGH IDLE
1. Carbon build-up on throttle plate
2. Engine idle speed too low
3. Worn or incorrectly gapped spark plugs
4. Worn or burned distributor rotor 5. Spark plug cables defective or crossed
6. Faulty coil
7. Intake manifold vacuum leak
ENGINE MISSES ON ACCELERATION
1. Worn or incorrectly gapped spark plugs
2. Spark plug cables defective or crossed
3. Dirt in fuel system 4. Burned, warped or pitted valves 5. Faulty coil
12. Test and replace, as necessary (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ IGNITION COIL - REMOVAL).
1. Remove throttle body and de-carbon. (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/THROTTLE BODY - REMOVAL). 2. Check Idle Air Control circuit. (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/ IDLE AIR CONTROL MOTOR - DESCRIPTION) 3. Replace or clean and re-gap spark plugs (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG - CLEANING) 4. Install new distributor rotor 5. Check for correct firing order or replace spark plug cables. (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ SPARK PLUG CABLE - DIAGNOSIS AND TESTING) 6. Test and replace, if necessary (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ IGNITION COIL - REMOVAL) 7. Inspect intake manifold gasket and vacuum hoses (Refer to 9 - ENGINE/ MANIFOLDS/INTAKE MANIFOLD - DIAGNOSIS AND TESTING).
1. Replace spark plugs or clean and set gap. (Refer to 8 - ELECTRICAL/IGNITION CONTROL/SPARK PLUG - CLEANING) 2. Replace or rewire secondary ignition cables. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/SPARK PLUG CABLE - REMOVAL) 3. Clean fuel system 4. Install new valves 5. Test and replace as necessary (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ IGNITION COIL - REMOVAL)
ENGINE - 5.9L
9 - 228
ENGINE - 5.9L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICALENGINE MECHANICAL DIAGNOSIS CHART
DR
CONDITION
POSSIBLE CAUSES
CORRECTION
NOISY VALVES/LIFTERS
1. High or low oil level in crankcase
2. Thin or diluted oil
3. Low oil pressure
4. Dirt in tappets/lash adjusters
5. Bent push rod(s) 6. Worn rocker arms
7. Worn tappets/lash adjusters
8. Worn valve guides
9. Excessive runout of valve seats or valve faces
1. Insufficient oil supply 2. Low oil pressure
3. Thin or diluted oil
4. Excessive connecting rod bearing clearance
5. Connecting rod journal out of round 6. Misaligned connecting rods
1. Insufficient oil supply 2. Low oil pressure
3. Thin or diluted oil
CONNECTING ROD NOISE
MAIN BEARING NOISE
1. Check for correct oil level. Adjust oil level by draining or adding as needed 2. Change oil. (Refer to 9 - ENGINE/ LUBRICATION/OIL - STANDARD PROCEDURE) 3. Check engine oil level. If ok, Perform oil pressure test. (Refer to 9 - ENGINE/LUBRICATION - DIAGNOSIS AND TESTING) for engine oil pressure test/specifications 4. Clean/replace hydraulic tappets/ lash adjusters 5. Install new push rods 6. Inspect oil supply to rocker arms and replace worn arms as needed 7. Install new hydraulic tappets/lash adjusters 8. Inspect all valve guides and replace as necessary 9. Grind valves and seats
1. Check engine oil level. 2. Check engine oil level. If ok, Perform oil pressure test. (Refer to 9 - ENGINE/LUBRICATION - DIAGNOSIS AND TESTING) engine oil pressure test/specifications 3. Change oil to correct viscosity. (Refer to 9 - ENGINE/LUBRICATION/ OIL - STANDARD PROCEDURE) for correct procedure/engine oil specifications 4. Measure bearings for correct clearance with plasti-gage. Repair as necessary 5. Replace crankshaft or grind journals 6. Replace bent connecting rods
1. Check engine oil level. 2. Check engine oil level. If ok, Perform oil pressure test. (Refer to 9 - ENGINE/LUBRICATION - DIAGNOSIS AND TESTING) 3. Change oil to correct viscosity.
DR ENGINE - 5.9L (Continued)
ENGINE - 5.9L
9 - 229
CONDITION
POSSIBLE CAUSES
CORRECTION
LOW OIL PRESSURE
OIL LEAKS
4. Excessive main bearing clearance
5. Excessive end play
6. Crankshaft main journal out of round or worn 7. Loose flywheel or torque converter
1. Low oil level 2. Faulty oil pressure sending unit 3. Clogged oil filter 4. Worn oil pump 5. Thin or diluted oil 6. Excessive bearing clearance
7. Oil pump relief valve stuck
8. Oil pickup tube loose, broken, bent or clogged 9. Oil pump cover warped or cracked
1. Misaligned or deteriorated gaskets 2. Loose fastener, broken or porous metal part 3. Front or rear crankshaft oil seal leaking 4. Leaking oil gallery plug or cup plug
EXCESSIVE OIL CONSUMPTION OR SPARK PLUGS OIL FOULED
1. CCV System malfunction
2. Defective valve stem seal(s) 3. Worn or broken piston rings
4. Scuffed pistons/cylinder walls
5. Carbon in oil control ring groove 6. Worn valve guides
7. Piston rings fitted too tightly in grooves
4. Measure bearings for correct clearance. Repair as necessary 5. Check crankshaft thrust bearing for excessive wear on flanges 6. Grind journals or replace crankshaft
7. Inspect crankshaft, flexplate/ flywheel and bolts for damage. Tighten to correct torque
1. Check oil level and fill if necessary 2. Install new sending unit 3. Install new oil filter 4. Replace oil pump assembly. 5. Change oil to correct viscosity. 6. Measure bearings for correct clearance 7. Remove valve to inspect, clean and reinstall 8. Inspect oil pickup tube and pump, and clean or replace if necessary 9. Install new oil pump
1. Replace gasket 2. Tighten, repair or replace the part
3. Replace seal
4. Remove and reseal threaded plug. Replace cup style plug
1. (Refer to 25 - EMISSIONS CONTROL/EVAPORATIVE EMISSIONS - DESCRIPTION) for correct operation 2. Repair or replace seal(s) 3. Hone cylinder bores. Install new rings 4. Hone cylinder bores and replace pistons as required 5. Remove rings and de-carbon piston 6. Inspect/replace valve guides as necessary 7. Remove rings and check ring end gap and side clearance. Replace if necessary
ENGINE - 5.9L
9 - 230
ENGINE - 5.9L (Continued) DIAGNOSIS AND TESTING—ENGINE DIAGNOSIS - LUBRICATIONDR
CONDITION
OIL LEAKS
POSSIBLE CAUSES
CORRECTION
1. Gaskets and O-Rings.
1.
(a) Misaligned or damaged. (b) Loose fasteners, broken or porous metal parts. 2. Crankshaft rear seal 3. Crankshaft seal flange. Scratched, nicked or grooved. 4. Oil pan flange cracked. 5.Front cover seal, damaged or misaligned. 6. Scratched or damaged vibration damper hub.
(a) Replace as necessary. (b) Tighten fasteners, Repair or replace metal parts. 2. Replace as necessary. 3. Polish or replace crankshaft.
4. Replace oil pan. 5. Replace seal.
6. Polish or replace damper.
OIL PRESSURE DROP
1. Low oil level.
1. Check and correct oil level.
2. Faulty oil pressure sending unit. 3. Low oil pressure.
4. Clogged oil filter. 5. Worn oil pump. 6. Thin or diluted oil. 7. Excessive bearing clearance. 8. Oil pump relief valve stuck. 9. Oil pickup tube loose or damaged.
2. Replace sending unit. 3. Check pump and bearing clearance. 4. Replace oil filter. 5. Replace as necessary. 6. Change oil and filter. 7. Replace as necessary. 8. Replace oil pump. 9. Replace as necessary.
OIL PUMPING AT RINGS; SPARK
1. Worn or damaged rings.
PLUGS FOULING
2. Carbon in oil ring slots. 3. Incorrect ring size installed. 4. Worn valve guides. 5. Leaking intake gasket. 6. Leaking valve guide seals.
1. Hone cylinder bores and replace rings. 2. Replace rings. 3. Replace rings. 4. Ream guides and replace valves. 5. Replace intake gaskets. 6. Replace valve guide seals.
DR ENGINE - 5.9L (Continued) DIAGNOSIS AND TESTING—CYLINDER COMPRESSION PRESSURE
The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunc- tions.
Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise, the indicated compression pressures may not be valid for diagnosis purposes.
(1) Clean the spark plug recesses with compressed
air.
(2) Remove the spark plugs (Refer to 8 - ELEC- TRICAL/IGNITION CONTROL/SPARK PLUG - REMOVAL).
(3) Secure the throttle in the wide-open position. (4) Disconnect the ignition coil. (5) Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions.
(6) Record the compression pressure on the third revolution. Continue the test for the remaining cylin- ders.
(Refer to 9 - ENGINE - SPECIFICATIONS) for the
correct engine compression pressures.
DIAGNOSIS AND TESTING - CYLINDER COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition. Combustion pressure leakage testing will detect: † Exhaust and intake valve leaks (improper seat- ing)† Leaks between adjacent cylinders or into water jacket
ENGINE - 5.9L
9 - 231
† Any causes for combustion/compression pressure
loss
WARNING: DO NOT REMOVE THE RADIATOR CAP WITH THE SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM HOT COOLANT CAN OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor- then turn OFF the
mal operating temperature, engine.
Remove the spark plugs. Remove the oil filler cap. Remove the air cleaner. Calibrate the tester according to the manufactur- er’s instructions. The shop air source for testing should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum and 552 kPa (80 psi) recom- mended.Perform the test procedure on each cylinder accord- ing to the tester manufacturer’s instructions. While testing, listen for pressurized air escaping through the throttle body, tailpipe or oil filler cap opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE: At 552 kPa (80 psi) input pres- sure, a minimum of 414 kPa (60 psi) should be main- tained in the cylinder CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART.
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
CONDITION
POSSIBLE CAUSE
CORRECTION
AIR ESCAPES THROUGH THROTTLE BODY AIR ESCAPES THROUGH TAILPIPE AIR ESCAPES THROUGH RADIATOR MORE THAN 50% LEAKAGE FROM ADJACENT CYLINDERS
MORE THAN 25% LEAKAGE AND AIR ESCAPES THROUGH OIL FILLER CAP OPENING ONLY
Intake valve bent, burnt, or not seated properly Exhaust valve bent, burnt, or not seated properly Head gasket leaking or cracked cylinder head or block Head gasket leaking or crack in cylinder head or block between adjacent cylinders Stuck or broken piston rings; cracked piston; worn rings and/or cylinder wall
Inspect valve and valve seat. Reface or replace, as necessary Inspect valve and valve seat. Reface or replace, as necessary Remove cylinder head and inspect. Replace defective part Remove cylinder head and inspect. Replace gasket, head, or block as necessary Inspect for broken rings or piston. Measure ring gap and cylinder diameter, taper and out-of-round. Replace defective part as necessary
ENGINE - 5.9L
9 - 232
ENGINE - 5.9L (Continued) STANDARD PROCEDURESTANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS
There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results. Do not use form-in- place gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket materials that are used in the engine area. Mopart Engine RTV GEN II, Mopart ATF-RTV, and Mopart Gasket Maker gasket materials, each have different properties and can not be used in place of the other.
MOPARt ENGINE RTV GEN II Mopart Engine RTV GEN II is used to seal com- ponents exposed to engine oil. This material is a spe- cially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.
MOPARt ATF RTV Mopart ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and seal- ing properties to seal components exposed to auto- matic coolants, and moisture. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.
transmission fluid,
engine
MOPARt GASKET MAKER Mopart Gasket Maker is an anaerobic type gasket material. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for use between two machined surfaces. Do not use on flexible metal flanges.
MOPARt GASKET SEALANT Mopart Gasket Sealant is a slow drying, perma- nently soft sealer. This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts under all temperatures. This mate- rial is used on engines with multi-layer steel (MLS) cylinder head gaskets. This material also will pre- vent corrosion. Mopart Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
DR
FORM-IN-PLACE GASKET AND SEALER APPLICATION
Assembling parts using a form-in-place gasket requires care but it’s easier than using precut gas- kets.
Mopart Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant to one gasket surface. Be certain the material sur- rounds each mounting hole. Excess material can eas- ily be wiped off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during assembly to prevent smear- ing material off the location.
Mopart Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 3 mm (0.120 in.) in diameter. All mounting holes must be circled. For corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towel. Components should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to prevent smearing material off the location.
Mopart Gasket Sealant in an aerosol can should be applied using a thin, even coat sprayed completely over both surfaces to be joined, and both sides of a gasket. Then proceed with assembly. Material in a can w/applicator can be brushed on evenly over the sealing surfaces. Material in an aerosol can should be used on engines with multi-layer steel gaskets.
STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain the original center line.
tially, this repair consists of:
Damaged or worn threads can be repaired. Essen- † Drilling out worn or damaged threads. † Tapping the hole with a special Heli-Coil Tap, or † Installing an insert into the tapped hole to bring
equivalent.
the hole back to its original thread size.
STANDARD PROCEDURE—HYDROSTATIC LOCK
CAUTION: DO NOT use the starter motor to rotate the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock (regardless of what caused the problem), follow the steps below.
ENGINE - 5.9L
9 - 233
strokes, depending on the bore condition, will be suf- ficient to provide a satisfactory surface. Using honing oil C-3501-3880, or a light honing oil, available from major oil distributors.
CAUTION: DO NOT use engine or transmission oil, mineral spirits, or kerosene.
(3) Honing should be done by moving the hone up and down fast enough to get a crosshatch pattern. The hone marks should INTERSECT at 40° to 60° for proper seating of rings (Fig. 3).
DR ENGINE - 5.9L (Continued)
(1) Perform the Fuel Pressure Release Procedure (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE).
(2) Disconnect the negative cable(s) from the bat-
tery.
(3) Inspect air
induction system, and intake manifold to ensure system is dry and clear of foreign material.
cleaner,
(4) Place a shop towel around the spark plugs to catch any fluid that may possibly be under pressure in the cylinder head. Remove the spark plugs.
(5) With all spark plugs removed, rotate the crank-
shaft using a breaker bar and socket.
(6) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
cylinders.
(7) Be sure all fluid has been removed from the
(8) Repair engine or components as necessary to
prevent this problem from occurring again.
(9) Squirt a small amount of engine oil into the cylinders to lubricate the walls. This will prevent damage on restart.
(10) Install new spark plugs. Tighten the spark
plugs to 41 N·m (30 ft. lbs.) torque.
(11) Drain engine oil. Remove and discard the oil
filter.
(12) Install the drain plug. Tighten the plug to 34
N·m (25 ft. lbs.) torque.
(13) Install a new oil filter. (14) Fill engine crankcase with the specified amount and grade of oil. (Refer to LUBRICATION & MAINTENANCE - SPECIFICATIONS).
(15) Connect the negative cable(s) to the battery. (16) Start the engine and check for any leaks.
STANDARD PROCEDURE - CYLINDER BORE HONING
Before honing, stuff plenty of clean shop towels under the bores and over the crankshaft to keep abrasive materials from entering the crankshaft area.
(1) Used carefully, the Cylinder Bore Sizing Hone C-823, equipped with 220 grit stones, is the best tool for this job. In addition to deglazing, it will reduce taper and out-of-round, as well as removing light scuffing, scoring and scratches. Usually, a few strokes will clean up a bore and maintain the required lim- its.
CAUTION: DO NOT use rigid type hones to remove cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done if the cylinder bore is straight and round. Use a cylin- der surfacing hone, Honing Tool C-3501, equipped with 280 grit stones (C-3501-3810). about 20-60
Fig.3CylinderBoreCrosshatchPattern
1 - CROSSHATCH PATTERN 2 - INTERSECT ANGLE
(4) A controlled hone motor speed between 200 and 300 RPM is necessary to obtain the proper cross- hatch angle. The number of up and down strokes per minute can be regulated to get the desired 40° to 60° angle. Faster up and down strokes increase the cross- hatch angle.
(5) After honing, it is necessary that the block be cleaned to remove all traces of abrasive. Use a brush to wash parts with a solution of hot water and deter- gent. Dry parts thoroughly. Use a clean, white, lint- free cloth to check that the bore is clean. Oil the bores after cleaning to prevent rusting.
REMOVAL
(1) Disconnect the battery negative cable. (2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
ENGINE - 5.9L
9 - 234
ENGINE - 5.9L (Continued)DR
from a/c
refrigerant
(3) Recover
if equipped (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING - STANDARD PROCEDURE). (4) Remove the a/c condenser, if equipped (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/ A/C CONDENSER - REMOVAL).
system,
(5) Remove the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS REMOVAL).
COOLER
(6) Remove the washer bottle from the fan shroud. (7) Remove the viscous fan/drive (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - REMOVAL). (8) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(9) Remove the upper crossmember and top core
support.
(10) Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(11) Remove the A/C compressor with the lines
attached. Secure compressor out of the way.
(12) Remove generator assembly (Refer to 8 - ELECTRICAL/CHARGING/GENERATOR - REMOV- AL).
(13) Remove the air cleaner resonator and duct
work as an assembly.
(14) Disconnect the throttle linkage (Refer to 14 - INJECTION/THROTTLE
SYSTEM/FUEL
FUEL CONTROL CABLE - REMOVAL).
(15) Remove throttle body (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/THROTTLE BODY - REMOVAL).
(16) Remove the intake manifold (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE REMOVAL).
(17) Remove the distributor cap and wiring. (18) Disconnect the heater hoses. (19) Disconnect
the power
steering hoses,
if
equipped.
(20) Perform the Fuel System Pressure Release procedure (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCEDURE).
(21) Disconnect the fuel supply line (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CON- NECT FITTING - STANDARD PROCEDURE).
(22) On Manual Transmission vehicles, remove the shift lever (Refer to 21 - TRANSMISSION/TRANS- AXLE/MANUAL/SHIFT COVER - REMOVAL).
(23) Raise and support the vehicle on a hoist and
drain the engine oil.
(24) Remove engine front mount thru-bolt nuts. (25) Disconnect the transmission oil cooler lines
from their retainers at the oil pan bolts.
(26) Disconnect exhaust pipe at manifolds.
(27) Disconnect the starter wires. Remove starter to 8 - ELECTRICAL/STARTING/
motor STARTER MOTOR - REMOVAL).
(Refer
(28) Remove the dust shield and transmission
inspection cover.
(29) Remove drive plate to converter bolts (Auto-
matic transmission equipped vehicles).
(30) Remove transmission bell housing to engine
block bolts.
(31) Lower the vehicle. (32) Install an engine lifting fixture. (33) Separate engine from transmission, remove engine from vehicle, and install engine assembly on a repair stand.
INSTALLATION
(1) Remove engine from the repair stand and posi- tion in the engine compartment. Position the thru- bolt into the support cushion brackets.
engine with transmission:
(2) Install engine lifting device. (3) Lower engine into compartment and align † Manual Transmission: Align clutch disc assem- bly (if disturbed). Install transmission input shaft into clutch disc while mating engine and transmis- sion surfaces. Install two transmission to engine block mounting bolts finger tight. † Automatic Transmission: Mate engine and trans- mission and install two transmission to engine block mounting bolts finger tight.
(4) Lower engine assembly until engine mount
through bolts rest in mount perches.
(5) Install remaining transmission to engine block
mounting bolts and tighten.
(6) Tighten engine mount through bolts. (7) Install drive plate to torque converter bolts.
(Automatic transmission models)
the starter and connect
(8) Install the dust shield and transmission cover. (9) Install the starter to 8 - ELECTRICAL/STARTING/ (Refer
wires STARTER MOTOR - INSTALLATION). (10) Install exhaust pipe to manifold. (11) Install the transmission cooler line brackets to
the oil pan.
(25 ft. lbs.) torque.
(12) Install the drain plug and tighten to 34 N·m
(13) Lower the vehicle. (14) Remove engine lifting fixture. (15) On Manual Transmission vehicles, install the shift lever (Refer to 21 - TRANSMISSION/TRANS- AXLE/MANUAL/SHIFT COVER - INSTALLATION). (16) Connect the fuel supply line (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CON- NECT FITTING - STANDARD PROCEDURE).
(17) Connect the power steering hoses, if equipped. (18) Connect the heater hoses.
DR ENGINE - 5.9L (Continued)
ENGINE - 5.9L
9 - 235
(19) Install the distributor cap and wiring. (20) Install
the intake manifold (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE INSTALLATION).
(21) Using a new gasket,
throttle body (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/ THROTTLE BODY - INSTALLATION).
install
(22) Connect the throttle linkage (Refer to 14 - INJECTION/THROTTLE
FUEL CONTROL CABLE - INSTALLATION).
SYSTEM/FUEL
(23) Install the air cleaner resonator and duct
work..
(24) Install the generator and wire connections (Refer to 8 - ELECTRICAL/CHARGING/GENERA- TOR - INSTALLATION).
(25) Install a/c compressor and lines (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C COMPRESSOR - INSTALLATION).
(26) Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(27) Install upper radiator support crossmember. (28) Install radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - INSTALLATION).
(29) Connect the radiator lower hose. (30) Connect the transmission oil cooler lines to
the radiator.
(31) Install the fan shroud. (32) Install the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
(33) Connect the radiator upper hose. (34) Install the washer bottle. (35) Install the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS INSTALLATION).
COOLER
(36) Connect the transmission cooler lines. (37) If equipped, install the condenser (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/ A/C CONDENSER - INSTALLATION).(38) Evacuate and charge the air conditioning sys- tem, if equipped (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO- CEDURE).
(39) Add engine oil to crankcase (Refer to LUBRI- CATION & MAINTENANCE/FLUID TYPES - SPEC- IFICATIONS).
(40) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(41) Connect battery negative cable. (42) Start engine and inspect for leaks. (43) Road test vehicle.
SPECIFICATIONS
5.9L ENGINE
ENGINE SPECIFICATIONS
DESCRIPTION
SPECIFICATION
GENERAL SPECIFICATIONS
Engine Type
90° V-8 OHV
Bore and Stroke
101.6 x 90.9 mm (4.00 x 3.58 in.)
Displacement
5.9L (360 c.i.)
Compression Ratio
9.1:1
Firing Order
Lubrication
1–8–4–3–6–5–7–2
Pressure Feed – Full
Flow
Filtration
Cooling System
Liquid Cooled – Forced
Cylinder Block
Cylinder Head
Crankshaft
Camshaft
Pistons
Circulation
Cast Iron
Cast Iron
Nodular Iron
Nodular Cast Iron
Aluminum Alloy w/strut
Connecting Rods
Forged Steel
Compression Pressure
689.5 kPa (100 psi)
(Min.)
CAMSHAFT
Bearing Diameter
No. 1
No. 2
No. 3
No. 4
No. 5
50.800 – 50.825 mm (2.000 – 2.001 in.) 50.394 – 50.419 mm (1.984 – 1.985 in.) 50.013 – 50.038 mm (1.969 – 1.970 in.) 49.606 – 49.632 mm (1.953 – 1.954 in.) 39.688 – 39.713 mm (1.5625 – 1.5635 in.)
ENGINE - 5.9L
9 - 236
ENGINE - 5.9L (Continued)DR
DESCRIPTION
SPECIFICATION
DESCRIPTION
SPECIFICATION
Bearing Journal Diameter No. 1
No. 2
No. 3
No. 4
No. 5
Bearing to Journal
Clearance
Standard
Service Limit
Camshaft End Play
50.723 – 50.775 mm (1.997 – 1.999 in.) 50.317 – 50.368 mm (1.981 – 1.983 in.) 49.936 – 49.987 mm (1.966 – 1.968 in.) 49.53 – 49.581 mm (1.950 – 1.952 in.) 39.611 – 39.662 mm (1.5595 – 1.5615 in.)
0.0254 – 0.0762 mm (0.001 – 0.003 in.) 0.127 mm (0.005 in.)
0.051 – 0.254 mm (0.002 – 0.010 in.)
CONNECTING RODS
Piston Pin bore Diameter
Side Clearance
24.966 – 24.978 mm (0.9829 – 0.9834 in.)
0.152 – 0.356 mm (0.006 – 0.014 in.)
CRANKSHAFT
Rod Journal
Diameter
Out of Round (Max.) Taper (Max.) Bearing Clearance
53.950 – 53.975 mm (2.124 – 2.125 in.)
0.0254 mm (0.001 in.) 0.0254 mm (0.001 in.)
0.013 – 0.056 mm
(0.0005 – 0.0022 in.)
Main Bearing Journal
Diameter
71.361 – 71.387 mm (2.8095 – 2.8105 in.)
Out of Round (Max.)
0.127 mm (0.001 in.)
Journals # 2 - 5
Service Limit
(0.0005 – 0.0015 in.)
0.013 – 0.051 mm (0.0005 – 0.002 in.)
Journal #1
Journals #2-50.0381 mm (0.0015 in.) 0.064 mm (0.0025 in.)
Crankshaft End Play
Service Limit
0.051 – 0.178 mm (0.002 – 0.007 in.) 0.254 mm (0.010 in.)
CYLINDER BLOCK
Cylinder Bore
Diameter
101.60 – 101.65 mm (4.000 – 4.002 in.)
Out of Round (Max.) Taper (Max.)
0.0254 mm (0.001 in.) 0.0254 mm (0.001 in.)
Lifter Bore
Diameter
22.99 – 23.01 mm
(0.9051 – 0.9059 in.)
Distributor Drive Bushing Press Fit
Bushing to Bore Interference
Shaft to Bushing Clearance
0.0127 – 0.3556 mm
(0.0005 – 0.0140 in.) 0.0178 – 0.0686 mm
(0.0007 – 0.0027 in.)
CYLINDER HEAD AND VALVES
Valve Seat
Angle
44.25° – 44.75°
Runout (Max.)
0.0762 mm (0.003 in.)
Width (Finish)
Intake
Exhaust
1.016 – 1.524 mm (0.040 – 0.060 in.) 1.524 – 2.032 mm (0.060 – 0.080 in.)
43.25° – 43.75°
Taper (Max.)
0.0254 mm (0.001 in.)
Valves
Bearing Clearance
Journal #1
0.013 – 0.038 mm
Face Angle
Head Diameter
DR ENGINE - 5.9L (Continued)
ENGINE - 5.9L
9 - 237
DESCRIPTION
SPECIFICATION
DESCRIPTION
SPECIFICATION
Intake Exhaust
47.752 mm (1.88 in.)
41.072 (1.617 in.)
Length (Overall)
Intake
Exhaust
126.21 – 126.85 mm (4.969 – 4.994 in.) 126.44 – 127.30 mm (4.978 – 5.012 in.)
Lift (@ zero lash)
Intake Exhaust
10.414 mm (0.410 in.) 10.592 mm (0.417 in.)
Stem Diameter
Intake
Exhaust
Guide Bore
Stem to Guide Clearance Intake
Exhaust
Service Limit
Valve Springs
9.449 - 9.474 mm (0.372 - 0.373 in.) 9.423 - 9.449 mm (0.371 - 0.372 in.)
9.500 - 9.525 mm (0.374 - 0.375 on.)
0.0254 - 0.0762 mm (0.001 - 0.003 in.) 0.0508 - 0.1016 mm (0.002 - 0.004 in.)
0.4318 - (0.017 in.)
Free Length
49.962 mm (1.967 in.)
Spring Tension
Valve closed
Valve open
378 N @ 41.66 mm (85 lbs. @ 1.64 in.) 890 N @ 30.89 mm (200 lbs. @ 1.212 in.)
Number of Coils
6.8
Installed Height
41.66 mm (1.64 in.)
Wire Diameter
4.50 mm (0.177 in.)
Dry Lash
Push Rod Length
(0.0011 - 0.0024 in.)
1.524 - 5.334 mm (0.060 - 0.210 in.)
175.64 - 176.15 mm (6.915 - 6.935 in.)
OIL PRESSURE
Curb Idle (Min.*)
41.4 kPa (6 psi)
@ 3000 rpm
207 - 552 kPa (30 - 80
psi)
Oil Pressure Bypass
Valve Setting
62 - 103 kPa (9 - 15 psi)
Switch Actuating
Pressure
34.5 - 48.3 kPa (5 - 7
psi)
* If oil pressure is zero at curb idle, DO NOT RUN ENGINE.
OIL PUMP
Clearance over Rotors
0.1016 mm (0.004 in.)
(Max.)
Cover Out of Flat (Max.)
0.0381 mm (0.0015 in.)
Inner Rotor Thickness
20.955 mm (0.825 in.)
(Min.)
Outer Rotor
Clearance (Max.) Diameter (Min.) Thickness (Min.)
0.3556 mm (0.014 in.) 62.7126 mm (2.469 in.) 20.955 mm (0.825 in.)
Tip Clearance between
Rotors (Max.)
0.2032 mm (0.008 in.)
PISTONS
Clearance at Top of Skirt
0.013 - 0.038 mm
Land Clearance (Diam.)
(0.0005 - 0.0015 in.)
0.508 - 0.660 mm (0.020 - 0.026 in.)
HYDRAULIC TAPPETS
Piston Length
81.03 mm (3.19 in.)
Body Diameter
22.949 - 22.962 mm (0.9035 - 0.9040 in.)
Clearance (to bore)
0.0279 - 0.0610 mm
Piston Ring Groove
Depth Groove #1 and 2
4.761 - 4.912 mm
ENGINE - 5.9L
9 - 238
ENGINE - 5.9L (Continued)DR
DESCRIPTION
SPECIFICATION
DESCRIPTION
SPECIFICATION
Groove #3
Weight
(0.187 - 0.193 in.) 3.996 - 4.177 mm (0.157 - 0.164 in.) 582 - 586 grams (20.53 - 20.67 oz.)
Intake Valve
Closes (ATDC) Opens (BBDC) Duration
Valve Overlap
62° 7° 249°
41°
PISTON PINS
Clearance in Piston
0.006 - 0.019 mm
OVERSIZE AND UNDERSIZE ENGINE
COMPONENT MARKINGS CHART
OS-US
Item
Identification
Location of Identification
U/S
Crankshaft
R or M M-2-3
Milled flat on
(0.00023 - 0.00074 in.)
25.007 - 25.015 mm (0.9845 - 0.9848 in.)
NONE
67.8 - 68.3 mm (2.67 - 2.69 in.)
PISTON RINGS
Diameter
End Play
Length
Ring Gap
Compression Ring (Top)
0.30 - 0.55 mm
(0.012 - 0.022 in.)
Compression Ring (2nd)
0.55 - 0.80 mm
Oil Control (Steel Rails)
Ring Side Clearance
(0.022 - 0.031 in.)
0.381 - 1.397 mm (0.015 - 0.055 in.)
Compression Rings
0.040 - 0.085 mm
.025 MM
(.001 in.)
O/S
.508 mm (.020 in.)
Cylinder Bores
(0.0016 - 0.0033 in.)
O/S
Tappets
Oil Ring (Steel Rails)
0.05 - 0.21 mm
MAX
(0.002 - 0.008 in.)
.203 mm (.008 in.)
ect.
(indicating No.
No. three
2 and
3 main bearing journal) and/or
R-1-4 ect.
(indicating No.
1 and
4 connecting
rod
journal)
crankshaft counter- weight.
Following
engine serial
number.
3/89
diamond -shaped stamp Top
pad
— Front of engine and
flat
ground on
outside surface
of each O/S tappet bore.
Ring Width Compression rings
Oil Ring (Steel Rails) Max.
1.530 - 1.555 mm (0.060 - 0.061 in.) 0.447 - 0.473 mm
(0.018 - 0.019 in.)
VALVE TIMING
Exhaust Valve
Closes (ATDC) Opens (BBDC) Duration
33° 56° 269°
O/S
Valve Stems
Milled pad
DR ENGINE - 5.9L (Continued)
ENGINE - 5.9L
9 - 239
DESCRIPTION
N·m
Ft. Lbs. 50
In. Lbs. —
Rear Insulator to Bracket Through-Bolt (2WD) Rear Insulator to Crossmember Support Bracket Nut (2WD) Rear Insulator to Crossmember Nuts (4WD) Rear Insulator to Transmission Bolts (4WD) Rear Insulator Bracket Bolts (4WD Automatic) Rear Support Bracket to Crossmember Flange Nuts Rear Support Plate to Transfer Case Bolts Rocker Arm Bolts Spark Plugs Starter Motor Mounting Bolts Thermostat Housing Bolts Throttle Body Bolts Torque Converter Drive Plate Bolts Transfer Case to Insulator Mounting Plate Nuts Transmission Support Bracket Bolts (2WD) Vibration Damper Bolt Water Pump to Timing Chain Case Cover Bolts
68
41
68
68
68
41
41
28
41
68
25
23
3130
50
50
50
30
30
21
30
50
— — —204
105
68
50
244
41180
30—
—
—
—
—
—
— — — 225
200
270—
—
— —
Item
Identification
Location of adjacent to
two
3/89 tapped
holes on
each end of cylinder head.
OS-US .127 mm
(.005 in.)
TORQUE
TORQUE CHART 5.9L ENGINE
DESCRIPTION
N·m
Camshaft Sprocket Bolt Camshaft Thrust Plate Bolts Timing Chain Case Cover Bolts Connecting Rod Cap Bolts Main Bearing Cap Bolts Crankshaft Pulley Bolts Cylinder Head Bolts
Step 1
Step 2Cylinder Head Cover Bolts Engine Support Bracket to Block Bolts (4WD) Exhaust Manifold to Cylinder Head Bolts/Nuts Flywheel Bolts Front Insulator Through bolt/nut Front Insulator to Support Bracket
Stud Nut (4WD) Through Bolt/Nut (4WD)
Front Insulator to Block Bolts (2WD) Generator Mounting Bolt Intake Manifold Bolts Oil Pan Bolts Oil Pan Drain Plug Oil Pump Attaching Bolts Oil Pump Cover Bolts
Ft. Lbs. 50
— 3045
85
—50
105
— 3025
55
7030
75
70In. Lbs. — 210
—— — 210
— — 95
——
— —
— — —
68
24
4161
115
2468
143
11
4134
75
9541
102
9530
41
— Refer to Procedure 24
215
— 34
— 41
11
95— 25
30
—ENGINE - 5.9L
9 - 240
ENGINE - 5.9L (Continued) SPECIAL TOOLS5.9L ENGINE
DR
OilPressureGaugeC-3292
EngineSupportFixtureC-3487–A
ValveSpringCompressorMD-998772–A
Adaptor6633
Adaptor6716A
ValveGuideSleeveC-3973
DialIndicatorC-3339
PullerC-3688
Puller1026
CrankshaftDamperRemovalInsert8513
DR ENGINE - 5.9L (Continued)
ENGINE - 5.9L
9 - 241
FrontOilSealInstaller6635
CrankshaftMainBearingRemoverC-3059
CamBearingRemover/InstallerC3132–A
CylinderBoreGaugeC-119
CamshaftHolderC-3509
PressureTesterKit7700
DistributorBushingPullerC-3052
Bloc–Check–KitC-3685–A
DistributorBushingDriver/BurnisherC-3053
ENGINESUPPORTFIXTURE8534
PistonRingCompressorC-385
9 - 242
ENGINE - 5.9L
DR
AIR CLEANER ELEMENT REMOVAL
Filter Element Only
(2) Lift entire housing assembly from 4 locating
pins (Fig. 5).
Housing removal is not necessary for element (fil-
ter) replacement.
at air cleaner cover.
(1) Loosen clamp (Fig. 4) and disconnect air duct
(2) Pry over 4 spring clips (Fig. 4) from housing
cover (spring clips retain cover to housing).
(3) Release housing cover from locating tabs on
housing (Fig. 4) and remove cover.
(4) Remove air cleaner element (filter) from hous-
(5) Clean inside of housing before replacing ele-
ing.
ment.
Fig.5AIRCLEANERHOUSING
1 - AIR CLEANER HOUSING ASSEMBLY 2 - LOCATING PINS (4)
INSTALLATION
(1) Install filter element into housing. (2) Position housing cover into housing locating
(3) Pry up 4 spring clips (Fig. 4) and lock cover to
tabs (Fig. 4).
housing.
(4) Install air duct to air cleaner cover and tighten
hose clamp to 3 N·m (30 in. lbs.) torque.
(5) If any other hose clamps were removed from air intake system, tighten them to 3.4 N·m (30 in. lbs.) torque.
(6) If any bolts were removed from air resonator housing or air intake tubing, tighten them to 4.5 N·m (40 in. lbs.) torque.
Fig.4AIRCLEANERHOUSINGCOVER
1 - CLAMP 2 - AIR DUCT 3 - AIR CLEANER COVER 4 - LOCATING TABS 5 - CLIPS (4)
Housing Assembly
(1) Loosen clamp (Fig. 4) and disconnect air duct
at air cleaner cover.
DR
ENGINE - 5.9L
9 - 243
CYLINDER HEAD
OPERATION
DESCRIPTION
DESCRIPTION—CYLINDER HEAD
The cast iron cylinder heads (Fig. 6) are mounted to the cylinder block using ten bolts. The spark plugs are located in the peak of the wedge between the valves.
OPERATION—CYLINDER HEAD
The cylinder head closes the combustion chamber allowing the pistons to compress the air fuel mixture to the correct ratio for ignition. The valves located in the cylinder head open and close to either allow clean air into the combustion chamber or to allow the exhaust gases out, depending on the stroke of the engine.
OPERATION - CYLINDER HEAD COVER GASKET
The steel-backed silicone gasket is designed to seal the cylinder head cover for long periods of time through extensive heat and cold, without failure. The gasket is designed to be reusable.
DIAGNOSIS AND TESTING—CYLINDER HEAD GASKET FAILURE
Fig.6CylinderHeadAssembly—V-8GasEngines 1 - EXHAUST VALVE 2 - SPARK PLUGS 3 - EXHAUST VALVES 4 - SPARK PLUGS 5 - EXHAUST VALVE 6 - INTAKE VALVES 7 - INTAKE VALVES
DESCRIPTION - CYLINDER HEAD COVER GASKET
The cylinder head cover gasket (Fig. 7) is a steel- backed silicone gasket, designed for long life usage.
Fig.7CylinderHeadCoverGasketV-8GasEngines 1 - CYLINDER HEAD COVER GASKET
A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket. † Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
− Loss of engine power − Engine misfiring − Poor fuel economy
† Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are:
− Engine overheating − Loss of coolant − Excessive steam (white smoke) emitting from
exhaust
− Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is leaking between adjacent cylinders, follow the proce- dures in Cylinder Compression Pressure Test in this section. An engine cylinder head gasket leaking between adjacent cylinders will result in approxi- mately a 50–70% reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRES- SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure cap. Start the engine and allow it to warm up until thermostat opens.
ENGINE - 5.9L
9 - 244
CYLINDER HEAD (Continued)If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST. EXCES- SIVE PRESSURE BUILT UP, BY CONTINUOUS ENGINE OPERATION, MUST BE RELEASED TO A SAFE PRESSURE POINT. NEVER PERMIT PRES- SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to pressure cap neck. Start the engine and observe the tester’s pressure gauge. If gauge pulsates with every power stroke of a cylinder a combustion pressure leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also be checked by using Bloc-Chek Kit C-3685-A or equivalent. Perform test following the procedures supplied with the tool kit.
REMOVAL
(1) Disconnect the battery negative cable. (2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the air cleaner resonator and duct
work.
(4) Remove
the
intake manifold-to-generator
bracket support rod. Remove the generator.
(5) Remove closed crankcase ventilation system. (6) Disconnect the evaporation control system. (7) Perform the Fuel System Pressure Release pro- cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV- ERY - STANDARD PROCEDURE). Disconnect the fuel supply line (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STAN- DARD PROCEDURE).
(8) Disconnect accelerator
so equipped, the speed control and transmission kick- down cables.
linkage and if
(9) Remove distributor cap and wires. (10) Disconnect the coil wires. (11) Disconnect heat indicator sending unit wire. (12) Disconnect heater hoses and bypass hose. (13) Remove the master
cylinder and booster
assembly. Refer to section 5 brakes.
(14) Remove cylinder head covers and gaskets (Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN- DER HEAD COVER(S) - REMOVAL).
(15) Remove
intake manifold (Refer
to 9 - ENGINE/MANIFOLDS/INTAKE REMOVAL) and throttle body as an assembly. Dis- card the flange side gaskets and the front and rear cross-over gaskets.
MANIFOLD
DR
(16) Remove exhaust manifolds (Refer
to 9 - ENGINE/MANIFOLDS/EXHAUST MANIFOLD - REMOVAL).
