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(17) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations.
(18) Remove the head bolts from each cylinder head and remove cylinder heads. Discard the cylin- der head gasket.
(19) Remove spark plugs.
CLEANING
Clean all surfaces of cylinder block and cylinder
heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
INSPECTION
Inspect all surfaces with a straightedge if there is any reason to suspect If out-of-flatness exceeds 0.00075mm/mm (0.0001in/in.) times the span length in any direction, either replace head or lightly machine the head surface.
leakage.
FOR EXAMPLE:—A 305 mm (12 in.) span is 0.102 mm (0.004 in.) out-of-flat. The allowable out-of- flat is 305 x 0.00075 (12 x 0.00075) equals 0.23 mm (0.009 in.). This amount of out-of-flat is acceptable.
The
cylinder head surface
finish should be
1.78-3.00 microns (70-125 microinches).
Inspect push rods. Replace worn or bent rods.
INSTALLATION
(1) Clean all surfaces of cylinder block and cylin-
der heads.
(2) Clean cylinder block front and rear gasket sur-
faces using a suitable solvent.
(3) Position new cylinder head gaskets onto the
cylinder block.
cylinder block.
(4) Position cylinder heads onto head gaskets and
(5) Starting at top center, tighten all cylinder head
bolts, in sequence (Fig. 8).
CAUTION: When tightening the rocker arm bolts, make sure the piston in that cylinder is NOT at TDC. Contact between the valves and piston could occur.
(6) Install push rods and rocker arm assemblies in their original position. Tighten the bolts to 28 N·m (21 ft. lbs.) torque.
(7) Install
the intake manifold (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE INSTALLATION) and throttle body assembly.
(8) Install
exhaust manifolds
to 9 - ENGINE/MANIFOLDS/EXHAUST MANIFOLD - INSTALLATION).
(Refer
DR CYLINDER HEAD (Continued)
ENGINE - 5.9L
9 - 245
CYLINDER HEAD COVER(S) REMOVAL
NOTE: A steel backed silicon gasket is used with the cylinder head cover (Fig. 9). This gasket can be used again.
Fig.8CylinderHeadBoltTighteningSequence (9) If required, adjust spark plugs to specifications. Install the plugs and tighten to 41 N·m (30 ft. lbs.) torque.
(10) Install coil wire. (11) Connect heat indicator sending unit wire. (12) Connect the heater hoses and bypass hose. (13) Install distributor cap and wires. (14) Connect
the accelerator linkage and if so equipped, the speed control and transmission kick- down cables.
(15) Install the fuel supply line (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CON- NECT FITTING - STANDARD PROCEDURE).
(16) Install the generator and drive belt (Refer to 7
- COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION). Tighten generator mounting bolt to 41 N·m (30 ft. lbs.) torque. Tighten the adjusting strap bolt to 23 N·m (200 in. lbs.) torque.(17) Install
the
intake manifold-to-generator
bracket support rod. Tighten the bolts.
(18) Place the cylinder head cover gaskets in posi- tion and install cylinder head covers (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
(19) Install closed crankcase ventilation system. (20) Connect the evaporation control system. (21) Reinstall
the master cylinder and booster
assembly. Refer to section 5 brakes.
(22) Install the air cleaner. (23) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(24) Connect the negative cable to the battery. (25) Start engine check for leaks.
Fig.9CylinderHeadCoverGasket
1 - CYLINDER HEAD COVER GASKET
(1) Disconnect the negative cable from the battery. (2) Disconnect the spark plug wires form the spark
plugs and set aside.
(3) Disconnect closed ventilation system and evap-
oration control system from cylinder head cover.
(4) Remove cylinder head cover and gasket.
CLEANING
Clean cylinder head cover gasket surface. Clean head rail, if necessary.
INSPECTION
Inspect cover for distortion and straighten, if nec-
essary.
Check the gasket for use in head cover installation.
If damaged, use a new gasket.
INSTALLATION
(1) The cylinder head cover gasket can be used
again. Install the gasket onto the head rail.
(2) Position the cylinder head cover onto the gas- ket. Tighten the bolts to 11 N·m (95 in. lbs.) torque. (3) Install closed crankcase ventilation system and
evaporation control system.
(4) Connect the spark plug wires to the spark
plugs.
(5) Connect the negative cable to the battery.
9 - 246
ENGINE - 5.9L
DR
(2) Attach dial indicator Tool C-3339 to cylinder head and set it at right angles to valve stem being measured (Fig. 11).
INTAKE/EXHAUST VALVES & SEATS DESCRIPTION
Both the intake and exhaust valves are made of steel. The intake valve is 48.768 mm (1.92 inches) in diameter and the exhaust valve is 41.148 mm (1.62
inches) in diameter and has a 2.032 mm (0.080 inch) wafer interia welded to the tip for durability. These valves are not splayed.STANDARD PROCEDURE—VALVES, GUIDES AND SPRINGS
VALVE CLEANING
Clean valves thoroughly. Discard burned, warped,
or cracked valves.
Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner.
VALVE GUIDES
Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 in.), replace the valve.
Measure valve stem guide clearance as follows: (1) Install Valve Guide Sleeve Tool C-3973 over valve stem and install valve (Fig. 10). The special sleeve places the valve at the correct height for checking with a dial indicator.
Fig.11MeasuringValveGuideWear
1 - VALVE 2 - SPECIAL TOOL C-3339
(3) Move valve to and from the indicator. The total dial indicator reading should not exceed 0.432 mm (0.017 in.). Ream the guides for valves with oversize stems if dial indicator reading is excessive or if the stems are scuffed or scored.
VALVE GUIDES
Service valves with oversize stems are available.
Refer to REAMER SIZES CHART
REAMER SIZES CHART
Fig.10PositioningValvewithToolC-3973
1 - VALVE 2 - SPACER TOOL
REAMER O/S
VALVE GUIDE SIZE
0.076 mm (0.003 in.) 0.381 mm (0.015 in.)
8.026 - 8.052 mm (0.316 - 0.317 in.) 8.331 - 8.357 mm (0.328 - 0.329 in.)
(1) Slowly turn reamer by hand and clean guide thoroughly before installing new valve. Ream the valve guides from standard to 0.381 mm (0.015
in.). Use a two step procedure so the valve guides are reamed true in relation to the valve seat:† Step 1—Ream to 0.0763 mm (0.003 inch). † Step 2—Ream to 0.381 mm (0.015 inch).DR INTAKE/EXHAUST VALVES & SEATS (Continued) REFACING VALVES AND VALVE SEATS
VALVES
ENGINE - 5.9L
9 - 247
The intake and exhaust valves have a 43-1/4° to 43-3/4° face angle and a 44-1/4° to 44-3/4° seat angle (Fig. 12).
Inspect the remaining margin after the valves are refaced (Fig. 13). Valves with less than 1.190 mm (0.047 in.) margin should be discarded.
Fig.12ValveFaceandSeatAngles
1 - CONTACT POINT A,B,C and D
Fig.13IntakeandExhaustValves
1 - MARGIN 2 - VALVE SPRING RETAINER LOCK GROOVE 3 - STEM 4 - FACE
VALVE FACE AND VALVE SEAT ANGLE CHART
VALVE SEATS
ITEM
DESCRIPTION
SPECIFICATION
SEAT WIDTH
INTAKE
EXHAUST
1.016 - 1.524 mm (0.040 - 0.060 in.) 1.524 - 2.032 mm (0.060 - 0.080 in.)
FACE ANGLE (INT. AND EXT.)
SEAT ANGLE (INT. AND EXT.)
CONTACT SURFACE
431⁄4° - 433⁄4°
441⁄4° - 443⁄4°
—
CAUTION: DO NOT un-shroud valves during valve seat refacing (Fig. 14).
Fig.14RefacingValveSeats
1 - STONE 2 - PILOT 3 - VALVE SEAT 4 - SHROUD
(1) When refacing valve seats, it is important that the correct size valve guide pilot be used for reseat-
ENGINE - 5.9L
9 - 248
INTAKE/EXHAUST VALVES & SEATS (Continued)ing stones. A true and complete surface must be obtained.
(2) Measure the concentricity of valve seat using a dial indicator. Total runout should not exceed 0.051
mm (0.002 in.) total indicator reading.(3) Inspect the valve seat with Prussian blue, to determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian blue then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of valve face, contact is satisfactory. If the blue is trans- ferred to the top edge of valve face, lower valve seat with a 15° stone. If the blue is transferred to bottom edge of valve face raise valve seat with a 60° stone. (4) When seat is properly positioned the width of intake seats should be 1.016-1.524 mm (0.040-0.060
in.). The width of the exhaust seats should be 1.524- 2.032 mm (0.060-0.080 in.).VALVE SPRINGS
Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested. As an example the compression length of the spring to be tested is 1-5/16 in.. Turn table of Universal Valve Spring Tester Tool until surface is in line with the 1-5/16 in. mark on the threaded stud. Be sure the zero mark is to the front (Fig. 15). Place spring over stud on the table and lift compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by 2. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Refer to specifications to obtain specified height and allowable tensions. Discard the springs that do not meet specifications.
Fig.15TestingValveSpringforCompressed
Length
1 - TORQUE WRENCH 2 - VALVE SPRING TESTER
DR
to 9 -
REMOVAL
(1) Remove the cylinder head (Refer ENGINE/CYLINDER HEAD - REMOVAL).
(2) Compress valve springs using Valve Spring
Compressor Tool MD- 998772A and adapter 6716A.
(3) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(4) Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to ensure installation in original location.
CLEANING
or cracked valves.
Clean valves thoroughly. Discard burned, warped,
Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner.
INSPECTION
Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 in.), replace the valve.
Measure valve stem guide clearance as follows: (1) Install Valve Guide Sleeve Tool C-3973 over valve stem and install valve (Fig. 16). The special sleeve places the valve at the correct height for checking with a dial indicator.
Fig.16PositioningValvewithToolC-3973
1 - VALVE 2 - SPACER TOOL
(2) Attach dial indicator Tool C-3339 to cylinder head and set it at right angles to valve stem being measured (Fig. 17).
(3) Move valve to and from the indicator. The total dial indicator reading should not exceed 0.432 mm (0.017 in.). Ream the guides for valves with oversize stems if dial indicator reading is excessive or if the stems are scuffed or scored.
INSTALLATION
(1) Clean valves
thoroughly. Discard burned,
warped and cracked valves.
(2) Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner.
DR INTAKE/EXHAUST VALVES & SEATS (Continued)
ENGINE - 5.9L
9 - 249
(3) Remove the push rods and place them on a
bench in the same order as removed.
Fig.17MeasuringValveGuideWear
1 - VALVE 2 - SPECIAL TOOL C-3339
(3) Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 inch), replace the valve.
(4) Coat valve stems with lubrication oil and insert
them in cylinder head.
(5) If valves or seats are reground, check valve stem height. If valve is too long, replace cylinder head.
(6) Install new seals on all valve guides. Install
valve springs and valve retainers.
(7) Compress valve springs with Valve Spring Compressor Tool MD-998772A and adapter 6716A, install locks and release tool. If valves and/or seats are ground, measure the installed height of springs. Make sure the measurement is taken from bottom of spring seat in cylinder head to the bottom surface of spring retainer. If spacers are installed, measure from the top of spacer. If height is greater than 42.86
mm (1-11/16 inches), install a 1.587 mm (1/16 inch) spacer in head counterbore. This should bring spring height back to normal 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch).(8) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
ROCKER ARM / ADJUSTER ASSEMBLY REMOVAL
(1) Remove cylinder head cover and gasket (Refer - ENGINE/CYLINDER HEAD/CYLINDER
to HEAD COVER(S) - REMOVAL).
(2) Remove the rocker arm bolts and pivots (Fig. 18). Place them on a bench in the same order as removed.
Fig.18RockerArms
1 - ROCKER ARMS 2 - CYLINDER HEAD
INSTALLATION
(1) Rotate the crankshaft until the “V8” mark lines up with the TDC mark on the timing chain case cover. This mark is located 147° ATDC from the No.1
firing position.(2) Install the push rods in the same order as
removed.
(3) Install rocker arm and pivot assemblies in the same order as removed. Tighten the rocker arm bolts to 28 N·m (21 ft. lbs.) torque.
CAUTION: DO NOT rotate or crank the engine dur- ing or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes).
(4) Install
cylinder head cover
to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
(Refer
ENGINE BLOCK CLEANING
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leakage.
INSPECTION
Examine block for cracks or fractures. The cylinder walls should be checked for out-of- round and taper. Refer to Honing Cylinder Bores in the Service Procedures portion of this Section.
Inspect the oil line plug, the oil line plug is located in the vertical passage at the rear of the block between the oil-to-filter and oil-from-filter passages (Fig. 19). Improper installation or missing plug could cause erratic, low, or no oil pressure.
The oil plug must come out the bottom. Use flat dowel, down the oil pressure sending unit hole from the top, to remove oil plug.
ENGINE - 5.9L
9 - 250
ENGINE BLOCK (Continued)(1) Remove oil pressure sending unit from back of
block.
(2) Insert a 3.175 mm (1/8 in.)
finish wire, or
equivalent, into passage.
(3) Plug should be 190.0 to 195.2 mm (7-1/2 to 7-11/16 in.) from machined surface of block (Fig. 19). If plug is too high, use a suitable flat dowel to posi- tion properly.
Fig.19OilLinePlug
1 - RIGHT OIL GALLERY 2 - CYLINDER BLOCK 3 - OIL FROM FILTER TO SYSTEM 4 - OIL TO FILTER 5 - FROM OIL PUMP 6 - CRANKSHAFT 7 - PLUG
(4) If plug is too low, remove oil pan and No. 4
main bearing cap. Use suitable flat dowel to position properly. Coat outside diameter of plug with Mopart Stud and Bearing Mount Adhesive. Plug should be 54.0 to 57.7 mm (2-1/8 to 2-5/16 in.) from bottom of the block.DR
CAMSHAFT & BEARINGS (IN BLOCK) REMOVAL—CAMSHAFT
NOTE: The camshaft has an integral oil pump and distributor drive gear (Fig. 20).
Fig.20CamshaftandSprocketAssembly
1 - THRUST PLATE 2 - OIL PUMP AND DISTRIBUTOR DRIVE GEAR INTEGRAL WITH CAMSHAFT 3 - CAMSHAFT SPROCKET
(1) Remove the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - REMOVAL).
(2) Remove the A/C Condenser (if equipped) (3) Remove the engine cover. (4) Remove intake manifold (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - REMOVAL).
(5) Remove cylinder head covers (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(6) Remove timing case cover
to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL) and timing chain (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL).(Refer
(7) Remove rocker arms. (8) Remove push rods and tappets. Identify each
part so it can be installed in its original location.
(9) Remove distributor and lift out the oil pump
and distributor drive shaft.
(10) Remove camshaft thrust plate, note location of
oil tab (Fig. 21).
(11) Install a long bolt into front of camshaft to aid in removal of the camshaft. Remove camshaft, being careful not to damage cam bearings with the cam lobes.
INSTALLATION—CAMSHAFT
(1) Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 51 mm (2
inches) of its final position in cylinder block.(2) Install Camshaft Holder Tool C-3509 with
tongue back of distributor drive gear (Fig. 22).
DR CAMSHAFT & BEARINGS (IN BLOCK) (Continued)
ENGINE - 5.9L
9 - 251
(5) Install timing chain and gears (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - INSTALLATION).
(6) Measure camshaft end play (Refer to 9 - ENGINE - SPECIFICATIONS). If not within limits install a new thrust plate.
(7) Each tappet reused must be installed in the same position from which it was removed. When camshaft is replaced, all of the tappets must be replaced.
(8) Install distributor and distributor drive shaft. (9) Install push rods and tappets. (10) Install rocker arms. (11) Install
to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
timing case cover
(Refer
(12) Install cylinder head covers (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
(13) Install intake manifold (Refer to 9 - ENGINE/ INSTALLA-
MANIFOLDS/INTAKE MANIFOLD - TION).
(14) Install the engine cover. (15) Install the A/C Condenser (if equipped) (16) Install the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION).
(17) Start engine check for leaks.
CONNECTING ROD BEARINGS STANDARD PROCEDURE - CONNECTING ROD BEARING FITTING
Fit all rods on a bank until completed. DO NOT alternate from one bank to another, because connect- ing rods and pistons are not interchangeable from one bank to another.
The bearing caps are not
should be marked at removal assembly.
interchangeable and to ensure correct
Each bearing cap has a small V-groove across the parting face. When installing the lower bearing shell, be certain that the V-groove in the shell is in line with the V-groove in the cap. This provides lubrica- tion of the cylinder wall in the opposite bank.
The bearing shells must be installed so that the tangs are in the machined grooves in the rods and caps.
Limits of taper or out-of-round on any crankshaft journals should be held to 0.025 mm (0.001 in.). Bearings are available in 0.025 mm (0.001 in.), 0.051
mm (0.002 in.), 0.076 mm (0.003 in.), 0.254 mm (0.010 in.) and 0.305 mm (0.012 in.) undersize. Install the bearings in pairs. DO NOT use a new bearing half with an old bearing half. DO NOT file the rods or bearing caps.Fig.21TimingChainOil
1 - THRUST PLATE FRONT SIDE 2 - CHAIN OIL TAB 3 - THRUST PLATE REAR SIDE
Fig.22CamshaftHoldingToolC-3509(Installed
Position)
1 - SPECIAL TOOL C-3509
2 - DRIVE GEAR 3 - DISTRIBUTOR LOCK BOLT(3) Hold tool in position with a distributor lock- plate bolt. This tool will restrict camshaft from being pushed in too far and prevent knocking out the welch plug in rear of cylinder block. Tool should remain installed until the camshaft and crankshaft sprockets and timing chain have been installed. (4) Install camshaft thrust plate and chain oil tab. Make sure tang enters lower right hole in thrust plate. Tighten bolts to 24 N·m (210 in. lbs.) torque. Top edge of tab should be flat against thrust plate in order to catch oil for chain lubrication.
9 - 252
ENGINE - 5.9L
CRANKSHAFT DESCRIPTION
The crankshaft (Fig. 23) is of a cast nodular steel splayed type design, with five main bearing journal- s.The crankshaft is located at the bottom of the engine block and is held in place with five main bear- ing caps. The number 3 counterweight is the location for journal size identification.
Fig.23CrankshaftwithJournalSizeIdentification OPERATION
The crankshaft transfers force generated by com- bustion within the cylinder bores to the flywheel or flexplate.
REMOVAL
NOTE: This procedure can be done in vehicle. How- ever the transmission must be removed first.
(1) If crankshaft is to be removed while engine is in vehicle remove the transmission. Refer to 21 - TRANSMISSION/TRANSAXLE.
(2) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(3) Remove the oil pump from the rear main bear- ing cap (Refer to 9 - ENGINE/LUBRICATION/OIL PUMP - REMOVAL).
(4) Remove the vibration damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL).
(5) Remove the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
(6) Identify rod bearing caps before removal.
Remove rod bearing caps with bearings.
DR
CAUTION: Support crankshaft before removing main bearing caps. failure to do so will allow the crankshaft to fall damaging the crankshaft.
(7) Using a suitable jack, support the crankshaft. (8) Identify main bearing caps before removal. Remove main bearing caps and bearings one at a time.
(9) Lower the crankshaft out of the block. (10) Remove and discard the crankshaft rear oil
(11) Remove and discard the front crankshaft oil
seals.
seal.
INSTALLATION
(1) Clean Gasket Maker residue and sealant from the cylinder block and rear cap mating surface. Do this before applying the Mopart Gasket Maker and the installation of rear cap.
(2) Lightly oil the new upper seal lips with engine
oil.
oil.
(3) Install the new upper rear bearing oil seal with the white paint facing towards the rear of the engine. (4) Position the crankshaft into the cylinder block. (5) Lightly oil the new lower seal lips with engine
(6) Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine.
(7) Apply 5 mm (0.20 in) drop of Mopart Gasket Maker, or equivalent, on each side of the rear main bearing cap (Fig. 24). DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assem- ble bearing cap to cylinder block immediately after sealant application.
Fig.24SealantApplicationtoBearingCap
1 - MOPART GASKET MAKER 5 mm (0.20 IN.) ON BOTH SIDES OF REAR MAIN CAP
DR CRANKSHAFT (Continued)
(8) To align the bearing cap, use cap slot, align- ment dowel and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than 2 times for proper engagement.
(9) Clean and oil all cap bolts. Install all main bearing caps. Install all cap bolts and alternately tighten to 115 N·m (85 ft. lbs.) torque.
(10) Install oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(11) Install the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
(12) Install the vibration damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).
(13) Position the connecting rods onto the crank- shaft and install the rod bearing caps. Tighten the nuts to 61 N·m (45 ft. lbs.).
(14) Apply Mopart Silicone Rubber Adhesive Seal- ant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing (Fig. 25). Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess seal- ant off the oil pan seal groove.
(15) Install new front crankshaft oil seal (Refer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - FRONT - INSTALLATION).
(16) Immediately install the oil pan (Refer to 9 - INSTALLA-
ENGINE/LUBRICATION/OIL PAN - TION).
Fig.25ApplySealanttoBearingCaptoBlockJoint 1 - MOPAR SILICONE RUBBER ADHESIVE SEALANT NOZZLE TIP 2 - SEALANT APPLIED 3 - CYLINDER BLOCK 4 - REAR MAIN BEARING CAP
(17) If the transmission was removed, install the transmission. Refer to 21 - TRANSMISSION/TRANS- AXLE.
ENGINE - 5.9L
9 - 253
CRANKSHAFT MAIN BEARINGS DESCRIPTION
Main bearings (Fig. 26) are located in the cylinder block. One half of the main bearing is located in the crankshaft main bore the other half of the matching bearing is located in the main bearing cap. there are five main bearings. Number three main bearing is flanged, this flange controls crankshaft thrust.
Fig.26MainBearingOrientation
OPERATION
The main bearings encircle the crankshaft main bearing journals, this aligns the crankshaft to the centerline of the engine and allows the crankshaft to turn without wobbling or shaking therefore eliminat- ing vibration. The main bearings are available in standard and undersizes.
STANDARD PROCEDURE—CRANKSHAFT MAIN BEARING FITTING
Bearing caps are not interchangeable and should be marked at removal to ensure correct assembly. Upper and lower bearing halves are NOT inter- changeable. Lower main bearing halves of No.2 and 4
are interchangeable.Upper and lower No.3 bearing halves are flanged to carry the crankshaft thrust loads. They are NOT interchangeable with any other bearing halves in the engine (Fig. 27). Bearing shells are available in stan- dard and the following undersizes: Never install an undersize bearing that will reduce clearance below specifications.
ENGINE - 5.9L
9 - 254
CRANKSHAFT MAIN BEARINGS (Continued)MainBearingUndersizeAvailabilityList
† 0.25 mm (0.001 inch) † 0.051 mm (0.002 inch) † 0.076 mm (0.003 inch) † 0.254 mm (0.010 inch) † 0.305 mm (0.012 inch)
DR
Fig.28UpperMainBearingRemovaland
InstallationwithToolC-3059
1 - SPECIAL TOOL C-3059
2 - BEARING 3 - SPECIAL TOOL C-3059
4 - BEARINGFig.27MainBearing
REMOVAL
(1) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(2) Remove the oil pump from the rear main bear- ing cap (Refer to 9 - ENGINE/LUBRICATION/OIL PUMP - REMOVAL).
(3) Identify bearing caps before removal. Remove
bearing caps one at a time.
(4) Remove upper half of bearing by inserting Crankshaft Main Bearing Remover/Installer Tool C-3059 into the oil hole of crankshaft (Fig. 28).
(5) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
INSTALLATION
Only one main bearing should be selectively fitted while all other main bearing caps are properly tight- ened. All bearing capbolts removed during service procedures are to be cleaned and oiled before instal- lation.
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
(1) Start bearing in place, and insert Crankshaft Main Bearing Remover/Installer Tool C-3059 into oil hole of crankshaft (Fig. 28).
(2) Slowly rotate crankshaft counterclockwise slid-
ing the bearing into position. Remove Tool C-3059.
(3) Install the bearing caps. Clean and oil the bolts. Tighten the capbolts to 115 N·m (85 ft. lbs.) torque.
(4) Install the oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(5) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
(6) Start engine check for leaks.
CRANKSHAFT OIL SEAL - FRONT DESCRIPTION
The crankshaft front seal is a one piece viton seal with a steel housing. The front seal is located in the engine front cover.
OPERATION
The crankshaft seals prevent oil from leaking from around the crankshaft, either from the rear of the engine or from the engine front cover.
REMOVAL
The oil seal can be replaced without removing the timing chain cover, provided that the cover is not misaligned.
(1) Disconnect the negative cable from the battery. (2) Remove vibration damper to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL).
(Refer
(3) If front seal is suspected of leaking, check front oil seal alignment to crankshaft. The seal installa- tion/alignment Tool 6635, should fit with minimum interference. If tool does not fit, the cover must be removed and installed properly.
DR CRANKSHAFT OIL SEAL - FRONT (Continued)
(4) Place a suitable tool behind the lips of the oil seal to pry the oil seal outward. Be careful not to damage the crankshaft seal bore of cover.
INSTALLATION
ENGINE - 5.9L
9 - 255
(1) Place the smaller diameter of the oil seal over Front Oil Seal Installation Tool 6635 (Fig. 29). Seat the oil seal in the groove of the tool.
(2) Position the seal and tool onto the crankshaft
(Fig. 30).
(3) Using the vibration damper bolt, tighten the bolt to draw the seal into position on the crankshaft (Fig. 31).
(4) Remove the vibration damper bolt and seal
installation tool.
damper.
(5) Inspect
the
seal
flange
on the vibration
(6) Install
the vibration damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).
(7) Connect the negative cable to the battery.
Fig.30PositionToolandSealontoCrankshaft
1 - SPECIAL TOOL 6635
2 - OIL SEAL 3 - TIMING CHAIN COVERFig.29PlacingOilSealonInstallationTool6635
1 - CRANKSHAFT FRONT OIL SEAL 2 - INSTALL THIS END INTO SPECIAL TOOL 6635
CRANKSHAFT OIL SEAL - REAR DESCRIPTION
The crankshaft rear seal is a two piece viton seal. One part of the two piece rear seal is located in a slot in the cylinder block oppsite the crankshaft main bearing cap, the second part of the two piece seal is located in the main bearing cap itself.
OPERATION
The crankshaft seals prevent oil from leaking from around the crankshaft, either from the rear of the engine or from the engine front cover.
Fig.31InstallingOilSeal
1 - SPECIAL TOOL 6635
2 - TIMING CHAIN COVERREMOVAL
The service seal is a two piece, Viton seal. The upper seal half can be installed with crankshaft removed from engine or with crankshaft installed. When a new upper seal is installed, install a new
ENGINE - 5.9L
9 - 256
CRANKSHAFT OIL SEAL - REAR (Continued)lower seal. The lower seal half can be installed only with the rear main bearing cap removed.
UPPER SEAL —CRANKSHAFT REMOVED
(1) Remove the crankshaft (Refer to 9 - ENGINE/ ENGINE BLOCK/CRANKSHAFT - REMOVAL). Dis- card the old upper seal.
UPPER SEAL—CRANKSHAFT INSTALLED
DR
bearing cap (Fig. 32). DO NOT over-apply sealant or allow the sealant to contact the rubber seal. Assem- ble bearing cap to cylinder block immediately after sealant application.
(1) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(2) Remove the oil pump (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - REMOVAL).
(3) Remove the rear main bearing cap. Remove
and discard the old lower oil seal.
(4) Carefully remove and discard the old upper oil
seal.
LOWER SEAL
(1) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(2) Remove the oil pump (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - REMOVAL).
(3) Remove the rear main bearing cap and discard
the old lower seal.
INSTALLATION
The service seal is a two piece, Viton seal. The upper seal half can be installed with crankshaft removed from engine or with crankshaft installed. When a new upper seal is installed, install a new lower seal. The lower seal half can be installed only with the rear main bearing cap removed.
UPPER SEAL —CRANKSHAFT REMOVED
(1) Clean the cylinder block rear cap mating sur- face. Be sure the seal groove is free of debris. Check for burrs at the oil hole on the cylinder block mating surface to rear cap.
(2) Lightly oil the new upper seal lips with engine
oil.
(3) Install the new upper rear bearing oil seal with the white paint facing toward the rear of the engine. (4) Position the crankshaft into the cylinder block. (5) Lightly oil the new lower seal lips with engine oil. (6) Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine.
(7) Apply 5 mm (0.20 in.) drop of Mopart Gasket Maker, or equivalent, on each side of the rear main
Fig.32SealantApplicationtoBearingCap 1 - MOPAR SILICONE RUBBER ADHESIVE SEALANT SLOTS 2 - MOPART GASKET MAKER (OR EQUIVALENT) 3 - CAP ALIGNMENT SLOT 4 - REAR MAIN BEARING CAP
(8) To align the bearing cap, use cap slot, align- ment dowel, and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than two times for proper engagement.
(9) Clean and oil all cap bolts. Install all main bearing caps. Install all cap bolts and alternately tighten to 115 N·m (85 ft. lbs.) torque.
(10) Install oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(11) Apply Mopart GEN II Silicone Rubber Adhe- sive Sealant, or equivalent, at bearing cap-to-block joint to provide cap to block and oil pan sealing (Fig. 33). Apply enough sealant so that a small amount is squeezed out. Withdraw nozzle and wipe excess seal- ant off the oil pan seal groove.
(12) Install new front crankshaft oil seal (Refer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - FRONT - INSTALLATION).
(13) Immediately install the oil pan (Refer to 9 - INSTALLA-
ENGINE/LUBRICATION/OIL PAN - TION).
DR CRANKSHAFT OIL SEAL - REAR (Continued)
ENGINE - 5.9L
9 - 257
(7) Install the rear main bearing cap with cleaned and oiled cap bolts. Alternately tighten ALL cap bolts to 115 N·m (85 ft. lbs.) torque.
(8) Install oil pump (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PUMP - INSTALLATION).
(9) Apply Mopart GEN II Silicone Rubber Adhe- sive Sealant, or equivalent, at bearing cap-to-block joint to provide cap-to-block and oil pan sealing (Fig. 33). Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess seal- ant off the oil pan seal groove.
(10) Immediately install the oil pan (Refer to 9 - INSTALLA-
ENGINE/LUBRICATION/OIL PAN - TION).
LOWER SEAL
(1) Clean the rear main cap mating surfaces
including the oil pan gasket groove.
(2) Carefully install a new upper seal. Refer to
UPPER SEAL—CRANKSHAFT INSTALLED.
(3) Lightly oil the new lower seal lips with engine
oil.
(4) Install a new lower seal in bearing cap with
the white paint facing the rear of engine.
(5) Apply 5 mm (0.20 in.) drop of Mopart Gasket Maker, or equivalent, on each side of the rear main bearing cap (Fig. 32). DO NOT over-apply sealant or allow the sealant to contact the rubber seal. Assem- ble bearing cap to cylinder block immediately after sealant application.
(6) To align the bearing cap, use cap slot, align- ment dowel, and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than two times for proper engagement.
(7) Install the rear main bearing cap with cleaned and oiled cap bolts. Alternately tighten the cap bolts to 115 N·m (85 ft. lbs.) torque.
(8) Install oil pump (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PUMP - INSTALLATION).
(9) Apply Mopart GEN II Silicone Rubber Adhe- sive Sealant, or equivalent, at bearing cap-to-block joint to provide cap to block and oil pan sealing. Apply enough sealant so that a small amount is squeezed out. Withdraw nozzle and wipe excess seal- ant off the oil pan seal groove.
(10) Immediately install the oil pan (Refer to 9 - INSTALLA-
ENGINE/LUBRICATION/OIL PAN - TION).
Fig.33ApplySealanttoBearingCap-to-BlockJoint 1 - MOPAR SILICONE RUBBER ADHESIVE SEALANT NOZZLE TIP 2 - SEALANT APPLIED 3 - CYLINDER BLOCK 4 - REAR MAIN BEARING CAP
UPPER SEAL—CRANKSHAFT INSTALLED
(1) Clean the cylinder block mating surfaces before oil seal installation. Check for burrs at the oil hole on the cylinder block mating surface to rear cap.
(2) Lightly oil the new upper seal lips with engine oil. To allow ease of installation of the seal, loosen at least the two main bearing caps forward of the rear bearing cap.
(3) Rotate the new upper seal into the cylinder block, being careful not to shave or cut the outer sur- face of the seal. To ensure proper installation, use the installation tool provided with the kit. Install the new seal with the white paint facing toward the rear of the engine.
(4) Install the new lower rear bearing oil seal into the bearing cap with the white paint facing toward the rear of the engine.
(5) Apply 5 mm (0.20 in.) drop of Mopart Gasket Maker, or equivalent, on each side of the rear main bearing cap (Fig. 32). DO NOT over-apply sealant or allow the sealant to contact the rubber seal. Assem- ble bearing cap to cylinder block immediately after sealant application. Be sure the white paint faces toward the rear of the engine.
(6) To align the bearing cap, use cap slot, align- ment dowel, and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than two times for proper engagement.
9 - 258
ENGINE - 5.9L
DR
DISTRIBUTOR BUSHING REMOVAL
CAUTION: This procedure MUST be followed when installing a new bushing or seizure to shaft may occur.
(1) Remove distributor (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/DISTRIBUTOR - REMOVAL). (2) Remove the intake manifold (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE REMOVAL).
(3) Insert Distributor Drive Shaft Bushing Puller Tool C-3052 into old bushing and thread down until a tight fit is obtained (Fig. 34).
(4) Hold puller screw and tighten puller nut until
bushing is removed.
Fig.36BurnishingDistributorDriveshaftBushing 1 - SPECIAL TOOL C-3053
2 - BUSHING(4) Install
the intake manifold (Refer to 9 -
MANIFOLD
ENGINE/MANIFOLDS/INTAKE INSTALLATION).
(5) Install the distributor (Refer to 8 - ELECTRI-
CONTROL/DISTRIBUTOR
CAL/IGNITION INSTALLATION).
Fig.34DistributorDriveshaftBushingRemoval
1 - SPECIAL TOOL C-3052
2 - BUSHINGINSTALLATION
(1) Slide new bushing over burnishing end of Dis- tributor Drive Shaft Bushing Driver/Burnisher Tool C-3053. Insert the tool and bushing into the bore.
(2) Drive bushing and tool into position, using a
hammer (Fig. 35).
HYDRAULIC LIFTERS DIAGNOSIS AND TESTING—HYDRAULIC TAPPETS
Before disassembling any part of the engine to cor- rect tappet noise, check the oil pressure. If vehicle has no oil pressure gauge, install a reliable gauge at the pressure sending-unit. The pressure should be between 207-552 kPa (30-80 psi) at 3,000 RPM.
level, check dipstick. The oil
Check the oil level after the engine reaches normal operating temperature. Allow 5 minutes to stabilize oil in the pan should never be above the FULL mark or below the ADD OIL mark on dipstick. Either of these two con- ditions could be responsible for noisy tappets.
level
Fig.35DistributorDriveshaftBushingInstallation 1 - SPECIAL TOOL C-3053
2 - BUSHING(3) As the burnisher is pulled through the bushing, the bushing is expanded tight in the block and bur- nished to correct size (Fig. 36). DO NOT ream this bushing.
OIL LEVEL
HIGH
If oil level is above the FULL mark, it is possible for the connecting rods to dip into the oil. With the engine running, this condition could create foam in the oil pan. Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to lose length and allow valves to seat noisily.
LOW
Low oil level may allow oil pump to take in air. When air is fed to the tappets, they lose length, which allows valves to seat noisily. Any leaks on
DR HYDRAULIC LIFTERS (Continued)
intake side of oil pump through which air can be drawn will create the same tappet action. Check the lubrication system from the intake strainer to the pump cover, including the relief valve retainer cap. When tappet noise is due to aeration, it may be intermittent or constant, and usually more than one tappet will be noisy. When oil level and leaks have been corrected, operate the engine at fast idle. Run engine for a sufficient time to allow all of the air inside the tappets to be bled out.
TAPPET NOISE DIAGNOSIS
(1) To determine source of tappet noise, operate
engine at idle with cylinder head covers removed.
(2) Feel each valve spring or rocker arm to detect noisy tappet. The noisy tappet will cause the affected spring and/or rocker arm to vibrate or feel rough in operation.
NOTE: Worn valve guides or cocked springs are sometimes mistaken for noisy tappets. If such is the case, noise may be dampened by applying side thrust on the valve spring. If noise is not apprecia- bly reduced, it can be assumed the noise is in the tappet. Inspect the rocker arm push rod sockets and push rod ends for wear.
(3) Valve tappet noise ranges from light noise to a heavy click. A light noise is usually caused by exces- sive leak-down around the unit plunger, or by the plunger partially sticking in the tappet body cylinder. The tappet should be replaced. A heavy click is caused by a tappet check valve not seating, or by for- eign particles wedged between the plunger and the tappet body. This will cause the plunger to stick in the down position. This heavy click will be accompa- nied by excessive clearance between the valve stem and rocker arm as valve closes. In either case, tappet assembly should be removed for inspection and clean- ing.
(4) The valve train generates a noise very much like a light tappet noise during normal operation. Care must be taken to ensure that tappets are mak- ing the noise. If more than one tappet seems to be noisy, it’s probably not the tappets.
LEAK-DOWN TEST
After cleaning and inspection, test each tappet for specified leak-down rate tolerance to ensure zero-lash operation (Fig. 37).
Swing the weighted arm of the hydraulic valve tap- pet tester away from the ram of the Universal Leak- Down Tester.
(1) Place a 7.925-7.950 mm (0.312-0.313 inch) diameter ball bearing on the plunger cap of the tap- pet.
ENGINE - 5.9L
9 - 259
(2) Lift the ram and position the tappet (with the
ball bearing) inside the tester cup.
(3) Lower the ram, then adjust the nose of the ram until it contacts the ball bearing. DO NOT tighten the hex nut on the ram.
(4) Fill the tester cup with hydraulic valve tappet
test oil until the tappet is completely submerged.
(5) Swing the weighted arm onto the push rod and pump the tappet plunger up and down to remove air. When the air bubbles cease, swing the weighted arm away and allow the plunger to rise to the normal position.
(6) Adjust the nose of the ram to align the pointer with the SET mark on the scale of the tester and tighten the hex nut.
(7) Slowly swing the weighted arm onto the push
rod.
(8) Rotate the cup by turning the handle at the base of the tester clockwise one revolution every 2
seconds.(9) Observe the leak-down time interval from the instant the pointer aligns with the START mark on the scale until the pointer aligns with the 0.125
mark. A normally functioning tappet will require 20-110 seconds to leak-down. Discard tappets with leak-down time interval not within this specification.Fig.37Leak-DownTester
1 - POINTER 2 - WEIGHTED ARM 3 - RAM 4 - CUP 5 - HANDLE 6 - PUSH ROD
REMOVAL
(1) Remove the air cleaner assembly and air in-let
hose.
(2) Remove cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
DR
PISTON & CONNECTING ROD DESCRIPTION
The pistons are made of aluminum and have three ring grooves, the top two grooves are for the compres- sion rings and the bottom groove is for the oil control ring. The connecting rods are forged steel and are coined prior to heat treat. The piston pins are press fit.
STANDARD PROCEDURE - PISTON FITTING
Piston and cylinder wall must be clean and dry. Specified clearance between the piston and the cylin- der wall is 0.013-0.038 mm (0.0005-0.0015 inch) at 21°C (70°F).
Piston diameter should be measured at the top of skirt, 90° to piston pin axis. Cylinder bores should be measured halfway down the cylinder bore and trans- verse to the engine crankshaft center line.
Pistons and cylinder bores should be measured at
normal room temperature, 21°C (70°F).
Check the pistons for taper and elliptical shape before they are fitted into the cylinder bore (Fig. 38).
ENGINE - 5.9L
9 - 260
HYDRAULIC LIFTERS (Continued)(3) Remove rocker assembly and push rods (Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER ARM / ADJUSTER ASSY - REMOVAL). Identify push rods to ensure installation in original locations.
(4) Remove intake manifold (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - REMOVAL).
(5) Remove yoke retainer and aligning yokes. (6) Slide Hydraulic Tappet Remover/Installer Tool C-4129-A through opening in cylinder head and seat tool firmly in the head of tappet.
(7) Pull tappet out of bore with a twisting motion. If all tappets are to be removed, identify tappets to ensure installation in original location.
(8) If the tappet or bore in cylinder block is scored, scuffed, or shows signs of sticking, ream the bore to next oversize. Replace with oversize tappet.
CLEANING
Clean tappet with a suitable solvent. Rinse in hot water and blow dry with a clean shop rag or com- pressed air.
INSTALLATION
(1) Lubricate tappets with Mopart Engine Oil
Supplement or equivalent.
(2) Install tappets and push rods in their original positions. Ensure that the oil feed hole in the side of the tappet body faces up (away from the crankshaft). (3) Install aligning yokes with ARROW toward
camshaft.
(4) Install yoke retainer. Tighten the bolts to 23
N·m (200 in. intake manifold (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI- FOLD - INSTALLATION).lbs.) torque. Install
(5) Install rocker arms (Refer to 9 - ENGINE/CYL- INDER HEAD/ROCKER ARM / ADJUSTER ASSY - INSTALLATION).
(6) Install
cylinder head cover
to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
(Refer
(7) Install air cleaner assembly and air in-let hose. (8) Start and operate engine. Warm up to normal
operating temperature.
CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all hydraulic tappets have filled with oil and have become quiet.
1 - 49.53 mm (1.95 IN.)
Fig.38PistonMeasurements
DR PISTON & CONNECTING ROD (Continued)
PISTON MEASUREMENT CHART
PISTON
A DIA = PISTON
SIZE
DIAMETER
BORE
DIAMETER
MIN. mm (in.)
—
MAX. mm (in.)
—
MIN. mm (in.)
—
MAX.
mm (in.)
—
101.580
101.592
101.605
101.618
(3.9992)
(3.9997)
(4.0002)
(4.0007)
101.592
101.605
101.618
101.630
(3.9997)
(4.0002)
(4.0007)
(4.0012)
101.605
101.618
101.630
101.643
(4.0002)
(4.0007)
(4.0012)
(4.0017)
—
—
—
—
DESCRIPTION
SPECIFICATION
PISTON PIN BORE
25.007 - 25.015 mm (.9845 - .9848 in.)
RING GROOVE
HEIGHT
OIL RAIL
COMPRESSION RAIL
4.033 - 4.058 mm (.1588 - .1598 in.) 1.529 - 1.554 mm
(.0602 - .0612 in.)
TOTAL FINISHED
470.8 ± 2 grams
WEIGHT
(16.607 ± .0706 ounces)
REMOVAL
(1) Remove the engine from the vehicle (Refer to 9
- ENGINE - REMOVAL).
(2) Remove the cylinder head (Refer ENGINE/CYLINDER HEAD - REMOVAL).
to 9 -
(3) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(4) Remove top ridge of cylinder bores with a reli- able ridge reamer before removing pistons from cyl- inder block. Be sure to keep tops of pistons covered during this operation.
(5) Be sure each connecting rod and connecting rod cap is identified with the cylinder number. Remove connecting rod cap. Install connecting rod bolt guide set on connecting rod bolts.
ENGINE - 5.9L
9 - 261
(6) Pistons and connecting rods must be removed from top of cylinder block. When removing the assemblies from the engine, rotate crankshaft so that the connecting rod is centered in cylinder bore and at BDC. Be careful not to nick crankshaft journals. (7) After removal, install bearing cap on the mat-
ing rod.
CLEANING
Clean the piston and connecting rod assembly
using a suitable solvent.
INSPECTION
Check the connecting rod journal
for excessive wear, taper and scoring (Refer to 9 - ENGINE/EN- GINE BLOCK/CONNECTING ROD BEARINGS - STANDARD PROCEDURE).
Check the connecting rod for signs of twist or bend-
ing.
Check the piston for taper and elliptical shape before it is fitted into the cylinder bore (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON & CONNECT- ING ROD - STANDARD PROCEDURE).
Check the piston for scoring, or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration.
INSTALLATION
(1) Be sure that compression ring gaps are stag- gered so that neither is in line with oil ring rail gap. (2) Before installing the ring compressor, be sure the oil ring expander ends are butted and the rail gaps located properly (Fig. 39).
Fig.39ProperRingInstallation
1 - OIL RING SPACER GAP 2 - SECOND COMPRESSION RING GAP OIL RING RAIL GAP (TOP) 3 - OIL RING RAIL GAP (BOTTOM) 4 - TOP COMPRESSION RING GAP
ENGINE - 5.9L
9 - 262
PISTON & CONNECTING ROD (Continued)DR
(b) Install the second compression rings using Installation Tool C-4184. The compression rings must be installed with the identification mark face up (toward top of piston) and chamfer facing down. An identification mark on the ring is a drill point, a stamped letter “O”, an oval depression, or the word “TOP” (Fig. 40) (Fig. 42).
(c) Using a ring installer, install the top com- pression ring with the chamfer facing up (Fig. 41) (Fig. 42). An identification mark on the ring is a drill point, a stamped letter “O”, an oval depression or the word “TOP” facing up.
(d) Measure side clearance between piston ring and ring land. Clearance should be 0.074-0.097 mm (0.0029-0.0038 in.) for the compression rings. The steel rail oil ring should be free in groove, but should not exceed 0.246 mm (0.0097 in.) side clearance.
(e) Pistons with insufficient, or excessive, side
clearance should be replaced.
(3) Immerse the piston head and rings in clean engine oil. Slide Piston Ring Compressor Tool C-385
over the piston and tighten with the special wrench (part of Tool C-385). Be sure position of rings does not change during this operation.(4) Install connecting rod bolt protectors on rod bolts. The long protector should be installed on the numbered side of the connecting rod.
(5) Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Be sure connecting rod and cylinder bore number are the same. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on crankshaft journal.
(7) The notch, or groove, on top of piston must be pointing toward front of engine. The larger chamfer of the connecting rod bore must be installed toward crankshaft journal fillet.
(8) Install rod caps. Be sure connecting rod, con- necting rod cap, and cylinder bore number are the same. Install nuts on cleaned and oiled rod bolts and tighten nuts to 61 N·m (45 ft. lbs.) torque.
(9) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION). the cylinder head (Refer
(10) Install
to 9 -
ENGINE/CYLINDER HEAD - INSTALLATION).
(11) Install the engine into the vehicle (Refer to 9 -
ENGINE - INSTALLATION).
PISTON RINGS STANDARD PROCEDURE - PISTON RING FITTING
Fig.40SecondCompressionRingIdentification
(Typical)
1 - SECOND COMPRESSION RING (BLACK CAST IRON) 2 - CHAMFER 3 - TWO DOTS
(1) Measurement of end gaps:
(a) Measure piston ring gap 2 in. from bottom of cylinder bore. An inverted piston can be used to push the rings down to ensure positioning rings squarely in the cylinder bore before measuring.
(b) Insert feeler gauge in the gap. The top com- pression ring gap should be between 0.254-0.508
mm (0.010-0.020 in.). The second compression ring gap 0.508-0.762 mm (0.020-0.030 in.). The oil ring gap should be 0.254- 1.270 mm (0.010-0.050 in.).between
should
be
(c) Rings with insufficient end gap may be prop- erly filed to the correct dimension. Rings with excess gaps should not be used. (2) Install rings, and confirm ring side clearance: (a) Install oil rings being careful not to nick or scratch the piston. Install the oil control rings accord- ing to instructions in the package. It is not necessary to use a tool to install the upper and lower rails. Insert oil rail spacer first, then side rails.
Fig.41TopCompressionRingIdentification(Typical) 1 - TOP COMPRESSION RING (GRAY IN COLOR) 2 - CHAMFER 3 - ONE DOT
(3) Orient the rings:
(a) Arrange top compression ring 90° counter-
clockwise from the oil ring rail gap (Fig. 43).
DR PISTON RINGS (Continued)
ENGINE - 5.9L
9 - 263
(6) Install Special Tool 1026 Three Jaw Puller onto
the vibration damper (Fig. 44).
Fig.42CompressionRingChamferLocation(Typical) 1 - CHAMFER 2 - TOP COMPRESSION RING 3 - SECOND COMPRESSION RING 4 - PISTON 5 - CHAMFER
(b) Arrange second compression ring 90° clock-
wise from the oil ring rail gap (Fig. 43).
Fig.43ProperRingInstallation
1 - OIL RING SPACER GAP 2 - SECOND COMPRESSION RING GAP OIL RING RAIL GAP (TOP) 3 - OIL RING RAIL GAP (BOTTOM) 4 - TOP COMPRESSION RING GAP
VIBRATION DAMPER REMOVAL
(1) Disconnect the battery negative cable. (2) Remove the cooling system fan (Refer to 7 - VISCOUS
DRIVE
COOLING/ENGINE/FAN CLUTCH - REMOVAL).
(3) Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(4) Remove vibration damper bolt and washer from
end of crankshaft.
crankshaft nose.
(5) Position Special Tool 8513 Insert
into the
Fig.44VibrationDamperRemoval
1 - SPECIAL TOOL 8513 INSERT 2 - SPECIAL TOOL 1026
(7) Pull vibration damper off of the crankshaft.
INSTALLATION
CAUTION: Thoroughly remove any contaminants from the crankshaft nose and the vibration damper bore. Failure to do so can cause sever damage to the crankshaft.
(1) Position the vibration damper onto the crankshaft. (2) Place installing tool, part of Puller Tool Set C-3688 in position and press the vibration damper onto the crankshaft (Fig. 45).
Fig.45VibrationDamperInstallation
1 - SPECIAL TOOL C-3688
(3) Install the crankshaft bolt and washer. Tighten
the bolt to 244 N·m (180 ft. lbs.) torque.
(4) Install the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(5) Position the fan shroud and install the bolts. Tighten the retainer bolts to 11 N·m (95 in. lbs.) torque. (6) Install the cooling fan (Refer to 7 - COOLING/ ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION).
(7) Connect the battery negative cable.
9 - 264
ENGINE - 5.9L
FRONT MOUNT REMOVAL
2WD
(1) Disconnect the negative cable from the battery.
CAUTION: Remove the viscous fan before raising engine. Failure to do so may cause damage to the fan blade, fan clutch and fan shroud.
(2) Remove the viscous fan (Refer to 7 - COOL- ING/ENGINE/FAN DRIVE VISCOUS CLUTCH - REMOVAL).
(3) Raise the vehicle. (4) Remove the engine oil filter. (5) Remove the oil drain trough. (6) Support the engine with a suitable jack and a block of wood across the full width of the engine oil pan.
(7) Support the front axle with a suitable jack. (8) Remove the (4) bolts that attach the engine
mounts to the front axle.
(9) Remove the (3) bolts that attach the front axle
to the left engine bracket.
(10) Lower the front axle. (11) Remove the through bolts
DR
(12) Raise the engine far enough to be able to
remove the left and right engine mounts.
(13) Remove the (8) mount to engine attaching bolts (14) Remove the engine mounts.
4WD
(1) Disconnect the negative cable from the battery.
CAUTION: Remove the viscous fan before raising engine. Failure to do so may cause damage to the fan blade, fan clutch and fan shroud.
(2) Remove the viscous fan (Refer to 7 - COOL- ING/ENGINE/FAN DRIVE VISCOUS CLUTCH - REMOVAL).
(3) Raise the vehicle. (4) Remove the skid plate. (5) Remove the front crossmember. (6) Remove the engine oil filter. (7) Remove the oil drain trough. (8) Support the engine with a suitable jack and a block of wood across the full width of the engine oil pan.
(9) Support the front axle with a suitable jack. (10) Remove the (4) bolts that attach the engine
mounts to the front axle (Fig. 46).
Fig.46ENGINEINSULATORMOUNTS4X4
1 - RH INSULATOR TO AXLE BOLT 2 - NUT 3 - PINION SUPPORT MOUNT 4 - LH INSULATOR MOUNT
5 - LH INSULATOR TO AXLE BOLT 6 - FRONT AXLE 7 - NUT 8 - RH INSULATOR MOUNT
DR FRONT MOUNT (Continued)
ENGINE - 5.9L
9 - 265
(11) Remove the (3) bolts that attach the front axle
to the left engine bracket.
(12) Lower the front axle. (13) Remove the (6) through bolts (14) Raise the engine far enough to be able to remove the left (Fig. 47) and right (Fig. 48) engine mounts.
Fig.48ENGINESUPPORTRH4X4
1 - BOLT 2 - ENGINE SUPPORT
Fig.47ENGINESUPPORTBRACKET5.9L
1 - ENGINE SUPPORT BRACKET 2 - BOLT 3 - BOLT
(15) Remove the engine mounts.
INSTALLATION
2WD
NOTE: For mount to engine block and left engine bracket to front axle bolts, apply MoparT Lock and Seal Adhesive, Medium Strength Threadlocker.
(1) Install the right and left side engine mounts to the engine block with (8) bolts. Torque bolts to 54
N·m (40 ft. lbs.).(2) Insert the (2) through bolts into the right and left side engine mounts and loose assemble the two nuts onto the through bolts.
(3) Lower the engine until the through bolts rest
onto the slots in the frame brackets.
(4) Tighten the through bolt nuts to 94 N·m (70 ft.
lbs.).
(5) Install the oil drain trough. (6) Install the engine oil filter. (7) Lower the vehicle. (8) Install the viscous fan (Refer to 7 - COOLING/ ENGINE/FAN DRIVE VISCOUS CLUTCH - REMOVAL).
(9) Reconnect the negative battery cable.
4WD
NOTE: For mount to engine block and left engine bracket to front axle bolts, apply MoparT Lock and Seal Adhesive, Medium Strength Threadlocker.
(1) Install the right and left side engine mounts to
the front axle. Torque nuts to 94 N·m (70 ft. lbs.).
(2) Raise the front axle into the frame and install the left and right side through bolts. Torque nuts to 94 N·m (70 ft. lbs.).
(3) Insert the two upper through bolts into the right and left side engine mounts and loose assemble the two nuts onto the through bolts.
(4) Lower the engine until the left and right side engine brackets rest on the through bolts, and the lower engine bracket through holes align with the engine mounts, and the left engine bracket holes align with the front axle slots (Fig. 49).
(5) Loose assemble the (3) bolts that attach the
front axle to the left engine bracket.
ENGINE - 5.9L
9 - 266
FRONT MOUNT (Continued)DR
Fig.49ENGINEINSULATORMOUNTS4X4
1 - RH INSULATOR TO AXLE BOLT 2 - NUT 3 - PINION SUPPORT MOUNT 4 - LH INSULATOR MOUNT
