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5 - LH INSULATOR TO AXLE BOLT 6 - FRONT AXLE 7 - NUT 8 - RH INSULATOR MOUNT
(6) Loose assemble the lower through bolts. (7) Torque the nuts for the (4) through bolts to 101
N·m (75 ft. lbs.).
(8) Torque the (3) bolts that attach the front axle
to the left engine bracket to 101 N·m (75 ft. lbs.).
(9) Install the oil drain trough. (10) Install the engine oil filter. (11) Install the front crossmember. (12) Install the skid plate. (13) Lower the vehicle. (14) Install the viscous fan (Refer to 7 - COOL- ING/ENGINE/FAN DRIVE VISCOUS CLUTCH - REMOVAL).
(15) Reconnect the negative battery cable.
REAR MOUNT REMOVAL
(1) Raise the vehicle on a hoist. (2) Using a suitable jack, support transmission. (3) Remove the nuts from the transmission mount
(Fig. 50).
(4) Remove the two bolts that attach the transmis-
sion mount to the engine bracket.
Fig.50TRANSMISSIONMOUNT
1 - MOUNT 2 - CROSSMEMBER 3 - NUT 4 - BOLT
DR REAR MOUNT (Continued)
ENGINE - 5.9L
9 - 267
OPERATION
The pump draws oil through the screen and inlet tube from the sump at the rear of the oil pan. The oil is driven between the drive and idler gears and pump body, then forced through the outlet to the block. An oil gallery in the block channels the oil to the inlet side of the full flow oil filter. After passing through the filter element, the oil passes from the center outlet of the filter through an oil gallery that channels the oil up to the main gallery, which extends the entire length on the right side of the block. The oil then goes down to the No. 1 main bear- ing, back up to the left side of the block, and into the oil gallery on the left side of the engine.
Galleries extend downward from the main oil gal- lery to the upper shell of each main bearing. The crankshaft is drilled internally to pass oil from the main bearing journals to the connecting rod journals. Each connecting rod bearing has half a hole in it, oil passes through the hole when the rods rotate and the hole lines up, oil is then thrown off as the rod rotates. This oil throwoff lubricates the camshaft lobes, distributor drive gear, cylinder walls, and pis- ton pins.
The hydraulic valve tappets receive oil directly from the main oil gallery. The camshaft bearings receive oil from the main bearing galleries. The front camshaft bearing journal passes oil through the cam- shaft sprocket to the timing chain. Oil drains back to the oil pan under the No. 1 main bearing cap.
The oil supply for the rocker arms and bridged pivot assemblies is provided by the hydraulic valve tappets, which pass oil through hollow push rods to a hole in the corresponding rocker arm. Oil from the rocker arm lubricates the valve train components. The oil then passes down through the push rod guide holes and the oil drain-back passages in the cylinder head, past the valve tappet area, and then returns to the oil pan (Fig. 52).
(5) Raise the transmission enough to remove the
mount from the crossmember.
(6) Remove the mount.
INSTALLATION
NOTE: Threadlocking compound must be applied to the bolts before installation.
(1) Install the two bolts that attach the transmis-
sion mount to the transmission bracket.
(2) Torque the bolts to 61N·m (45 ft.lbs.) torque. (3) Lower the transmission so the transmission mount rests on the crossmember, and the studs of the transmission mount are aligned in the slots in the crossmember.
(4) Install the nuts onto the transmission mount
studs through the crossmember access slot. (5) Torque the nuts to 54N·m (40 ft. lbs.).
LUBRICATION DESCRIPTION
A gear-type positive displacement pump (Fig. 51) is mounted at the underside of the rear main bearing cap. The pump uses a pick-up tube and screen assembly to gather engine oil from the oil pan.
Fig.51PositiveDisplacementOilPump—Typical 1 - INNER ROTOR AND SHAFT 2 - BODY 3 - DISTRIBUTOR DRIVESHAFT (REFERENCE) 4 - COTTER PIN 5 - RETAINER CAP 6 - SPRING 7 - RELIEF VALVE 8 - LARGE CHAMFERED EDGE 9 - BOLT 10 - COVER 11 - OUTER ROTOR
ENGINE - 5.9L
9 - 268
LUBRICATION (Continued)DR
1 - OIL DEFLECTOR TAB 2 - BOLT 3 - ROCKER ARM PIVOT 4 - ROCKER ARM 5 - DRIP OILING FOR VALVE TIP 6 - CYLINDER HEAD BOSS 7 - TO MAIN BEARINGS 8 - TO CAMSHAFT BEARINGS 9 - ROCKER ARM 10 - HOLLOW PUSH ROD 11 - TAPPET 12 - TO CONNECTING ROD BEARINGS 13 - OIL INTAKE
Fig.52OilLubricationSystem
14 - OIL PUMP 15 - OIL FILTER 16 - CRANKSHAFT 17 - FROM OIL PUMP 18 - OIL TO FILTER 19 - OIL FROM FILTER TO SYSTEM 20 - PASSAGE TO CAMSHAFT REAR BEARING 21 - RIGHT OIL GALLERY 22 - PLUG 23 - OIL PASSAGE FOR OIL PRESSURE INDICATOR LIGHT 24 - OIL SUPPLY VIA HOLLOW PUSH ROD SUPPLY IS FROM OIL GALLERY METERED THROUGH HYDRAULIC TAPPET 25 - OIL SUPPLY FROM HOLLOW PUSH ROD
DR LUBRICATION (Continued) DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING—ENGINE OIL LEAKS
Begin with a through visual
inspection of the engine, particularly at the area of the suspected leak. If an oil leak source is not readily identifiable, the following steps should be followed:
(1) Do not clean or degrease the engine at this time because some solvents may cause rubber to swell, temporarily stopping the leak.
(2) Add an oil-soluble dye (use as recommended by manufacturer). Start the engine and let idle for approximately 15 minutes. Check the oil dipstick to be sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light source. (3) Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil leak. If the oil leak is found and identified, repair per service manual instructions.
(4) If dye is not observed, drive the vehicle at var- ious speeds for approximately 24km (15 miles), and repeat previous step.
(5) If the oil leak source is not positively identified at this time, proceed with the air leak detection test method as follows:
(6) Disconnect the breather cap to air cleaner hose at the breather cap end. Cap or plug breather cap nipple.
(7) Remove the PCV valve from the cylinder head
cover. Cap or plug the PCV valve grommet.
(8) Attach an air hose with pressure gauge and
regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to more than 20.6 kpa (3 PSI) of test pressure.
(9) Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus- pected source. Adjust the regulator to the suitable test pressure that provide the best bubbles which will pinpoint the leak source. If the oil leak is detected and identified, repair per service manual procedures.(10) If the leakage occurs at the rear oil seal area, refer to the section, Inspection for Rear Seal Area Leak.
(11) If no leaks are detected, turn off the air sup- ply and remove the air hose and all plugs and caps. Install the PCV valve and breather cap hose. Proceed to next step.
(12) Clean the oil off the suspect oil
leak area using a suitable solvent. Drive the vehicle at various speeds approximately 24 km (15 miles). Inspect the engine for signs of an oil leak by using a black light.
ENGINE - 5.9L
9 - 269
DIAGNOSIS AND TESTING—ENGINE OIL PRESSURE
(1) Remove oil pressure sending unit. (2) Install Oil Pressure Line and Gauge Tool C-3292. Start engine and record pressure. (Refer to 9
- ENGINE - SPECIFICATIONS).OIL STANDARD PROCEDURE - ENGINE OIL
OIL LEVEL INDICATOR (DIPSTICK)
The engine oil level indicator is located at the right
front of the engine, left of the generator (Fig. 53).
Fig.53OilLevelIndicatorLocation
1 - CYLINDER HEAD COVER 2 - ENGINE OIL FILL CAP 3 - DIPSTICK 4 - ENGINE OIL FILTER 5 - FILTER BOSS
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil, oil foaming and oil pressure loss can result.
To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick.
(1) Position vehicle on level surface. (2) With engine OFF, allow approximately ten min- utes for oil to settle to bottom of crankcase, remove engine oil dipstick.
(3) Wipe dipstick clean. (4) Install dipstick and verify it is seated in the
tube.
(5) Remove dipstick, with handle held above the
tip, take oil level reading.
ENGINE - 5.9L
9 - 270
OIL (Continued)(6) Add oil only if level is below the ADD mark on
dipstick.
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals described in the Maintenance Schedule. This infor- mation can be found in the owner’s manual.
TO CHANGE ENGINE OIL
DR
Run engine until achieving normal operating tem-
(1) Position the vehicle on a level surface and turn
(2) Hoist vehicle. (3) Remove oil fill cap. (4) Place a suitable drain pan under crankcase
perature.
engine off.
drain.
(5) Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged.
(6) Install drain plug in crankcase. (7) Change oil filter (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - REMOVAL).
(8) Lower vehicle and fill crankcase with specified type (Refer to LUBRICATION & MAINTENANCE/ FLUID TYPES - DESCRIPTION) and amount of engine oil (Refer to LUBRICATION & MAINTE- NANCE - SPECIFICATIONS).
(9) Install oil fill cap. (10) Start engine and inspect for leaks. (11) Stop engine and inspect oil level.
OIL FILTER REMOVAL
All engines are equipped with a high quality full- flow, disposable type oil filter. DaimlerChrysler Cor- poration recommends a Mopart or equivalent oil filter be used.
(1) Position a drain pan under the oil filter. (2) Using a suitable oil filter wrench loosen filter. (3) Rotate the oil filter counterclockwise to remove
it from the cylinder block oil filter boss (Fig. 54).
(4) When filter separates from adapter nipple, tip gasket end upward to minimize oil spill. Remove fil- ter from vehicle.
(5) With a wiping cloth, clean the gasket sealing
surface (Fig. 55) of oil and grime.
(6) Install new filter (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - INSTALLATION).
INSTALLATION
(1) Lightly lubricate oil filter gasket with engine
oil or chassis grease.
Fig.54OilFilterRemoval—Typical
1 - ENGINE OIL FILTER 2 - OIL FILTER WRENCH
(2) Thread filter onto adapter nipple. When gasket makes contact with sealing surface, (Fig. 55) hand tighten filter one full turn, do not over tighten.
(3) Add oil (Refer to 9 - ENGINE/LUBRICATION/
OIL - STANDARD PROCEDURE).
Fig.55OilFilterSealingSurface—Typical
1 - SEALING SURFACE 2 - RUBBER GASKET 3 - OIL FILTER
OIL PAN REMOVAL
(1) Disconnect the negative cable from the battery. (2) Remove engine oil dipstick. (3) Raise vehicle. (4) Drain engine oil. (5) Remove exhaust pipe. (6) Remove left engine to transmission strut. (7) Loosen the right side engine support bracket cushion thru-bolt nut and raise the engine slightly. Remove oil pan by sliding backward and out.
(8) Remove the one-piece gasket.
CLEANING
Clean the block and pan gasket surfaces.
DR OIL PAN (Continued)
ENGINE - 5.9L
9 - 271
Trim or remove excess sealant film in the rear main cap oil pan gasket groove. DO NOT remove the sealant inside the rear main cap slots.
If present, trim excess sealant from inside the
Clean oil pan in solvent and wipe dry with a clean
engine.
cloth.
Clean oil screen and pipe thoroughly in clean sol-
vent. Inspect condition of screen.
INSPECTION
Inspect oil drain plug and plug hole for stripped or
damaged threads. Repair as necessary.
Inspect oil pan mounting flange for bends or distor-
tion. Straighten flange, if necessary.
INSTALLATION
(1) Clean the block and pan gasket surfaces. (2) Trim or remove excess sealant film in the rear main cap oil pan gasket groove. DO NOT remove the sealant inside the rear main cap slots.
(3) If present, trim excess sealant from inside the
engine.
(4) Fabricate 4 alignment dowels from 5/16 x 1 1/2
inch bolts. Cut the head off the bolts and cut a slot into the top of the dowel. This will allow easier installation and removal with a screwdriver (Fig. 56).Fig.56FabricationofAlignmentDowels
1 - 5/16” X 11⁄2” BOLT 2 - DOWEL 3 - SLOT
Fig.57PositionofDowelsinCylinderBlock
1 - DOWEL 2 - DOWEL 3 - DOWEL 4 - DOWEL
(10) Remove the dowels. Install the remaining oil pan bolts. Tighten these bolts to 24 N·m (215 in. lbs.) torque.
(11) Lower the engine into the support cushion brackets and tighten the thru bolt nut to the proper torque.
(12) Install the drain plug. Tighten drain plug to
34 N·m (25 ft. lbs.) torque.
(13) Install the engine to transmission strut. (14) Install exhaust pipe. (15) Lower vehicle. (16) (17) Connect the negative cable to the battery. (18) Fill crankcase with oil to proper level.
Install dipstick.
(5) Install the dowels in the cylinder block (Fig.
57).
(6) Apply small amount of Mopart Silicone Rubber Adhesive Sealant, or equivalent in the corner of the cap and the cylinder block.
(7) Slide the one-piece gasket over the dowels and
(8) Position the oil pan over the dowels and onto
onto the block.
the gasket.
(9) Install the oil pan bolts. Tighten the bolts to 24
N·m (215 in. lbs.) torque.
9 - 272
ENGINE - 5.9L
OIL PUMP REMOVAL
DR
(1) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(2) Remove the oil pump from rear main bearing
cap.
DISASSEMBLY
(1) Remove the relief valve as follows:
(a) Remove cotter pin. Drill a 3.175 mm (1/8
inch) hole into the relief valve retainer cap and insert a self-threading sheet metal screw.(b) Clamp screw into a vise and while support- ing oil pump, remove cap by tapping pump body using a soft hammer. Discard retainer cap and remove spring and relief valve (Fig. 58).
Fig.58OilPressureReliefValve
1 - OIL PUMP ASSEMBLY 2 - COTTER PIN 3 - RELIEF VALVE 4 - RETAINER CAP 5 - SPRING
(2) Remove oil pump cover (Fig. 59). (3) Remove pump outer rotor and inner rotor with
shaft (Fig. 59).
(4) Wash all parts in a suitable solvent and inspect
carefully for damage or wear.
Fig.59OilPump
1 - INNER ROTOR AND SHAFT 2 - BODY 3 - DISTRIBUTOR DRIVESHAFT (REFERENCE) 4 - COTTER PIN 5 - RETAINER CAP 6 - SPRING 7 - RELIEF VALVE 8 - LARGE CHAMFERED EDGE 9 - BOLT 10 - COVER 11 - OUTER ROTOR
INSPECTION
Mating surface of the oil pump cover should be smooth. Replace pump assembly if cover is scratched or grooved.
Lay a straightedge across the pump cover surface (Fig. 60). If a 0.038 mm (0.0015 inch) feeler gauge can be inserted between cover and straightedge, pump assembly should be replaced.
Fig.60CheckingOilPumpCoverFlatness
1 - COVER 2 - STRAIGHT EDGE 3 - FEELER GAUGE
DR OIL PUMP (Continued)
Measure thickness and diameter of OUTER rotor. If outer rotor thickness measures 20.9 mm (0.825
inch) or less or if the diameter is 62.7 mm (2.469
inches) or less, replace outer rotor (Fig. 61).ENGINE - 5.9L
9 - 273
Fig.63MeasuringOuterRotorClearanceinHousing
1 - PUMP BODY 2 - OUTER ROTOR 3 - FEELER GAUGE
Fig.61MeasuringOuterRotorThickness
If inner rotor measures 20.9 mm (0.825 inch) or less, replace inner rotor and shaft assembly (Fig. 62).
Fig.62MeasuringInnerRotorThickness
Fig.64MeasuringClearanceBetweenRotors
1 - OUTER ROTOR 2 - FEELER GAUGE 3 - INNER ROTOR
Slide outer rotor into pump body. Press rotor to the side with your fingers and measure clearance between rotor and pump body (Fig. 63). If clearance is 0.356 mm (0.014 inch) or more, replace oil pump assembly.
Install inner rotor and shaft into pump body. If clearance between inner and outer rotors is 0.203
mm (0.008 inch) or more, replace shaft and both rotors (Fig. 64).Place a straightedge across the face of the pump, between bolt holes. If a feeler gauge of 0.102 mm (0.004 inch) or more can be inserted between rotors and the straightedge, replace pump assembly (Fig. 65).
Inspect oil pressure relief valve plunger for scoring and free operation in its bore. Small marks may be removed with 400-grit wet or dry sandpaper.
Fig.65MeasuringClearanceOverRotors
1 - STRAIGHT EDGE 2 - FEELER GAUGE
ENGINE - 5.9L
9 - 274
OIL PUMP (Continued)The relief valve spring has a free length of approx- imately 49.5 mm (1.95 inches). The spring should test between 19.5 and 20.5 pounds when compressed to 34 mm (1-11/32 inches). Replace spring that fails to meet these specifications (Fig. 66).
If oil pressure was low and pump is within specifi- cations, inspect for worn engine bearings or other reasons for oil pressure loss.
DR
INTAKE MANIFOLD DESCRIPTION
The aluminum intake manifold (Fig. 67) is a single plane design with equal length runners and uses a separate plenum, therefore the manifold does have a plenum gasket. It also uses separate flange gaskets and front and rear cross-over gaskets. Extreme care must be used when sealing the gaskets to ensure that excess sealant does not enter the intake runners causing a restriction. Whenever the intake manifold is removed inspect the plenum pan for evidence of excess oil buildup, this condition indicates that the plenum pan gasket is leaking.
Fig.66ProperInstallationofRetainerCap
1 - RETAINER CAP 2 - CHAMFER 3 - COTTER KEY
ASSEMBLY
(1) Install pump rotors and shaft, using new parts
as required.
(2) Position the oil pump cover onto the pump lbs.)
body. Tighten cover bolts to 11 N·m (95 in. torque.
(3) Install the relief valve and spring. Insert the
cotter pin.
(4) Tap on a new retainer cap. (5) Prime oil pump before installation by filling
rotor cavity with engine oil.
INSTALLATION
(1) Install oil pump. During installation slowly rotate pump body to ensure driveshaft-to-pump rotor shaft engagement.
(2) Hold the oil pump base flush against mating surface on No.5 main bearing cap. Finger tighten pump attaching bolts. Tighten attaching bolts to 41
N·m (30 ft. lbs.) torque.(3) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
Fig.67IntakeManifoldandThrottleBody—V-8Gas
EnginesTypical
1 - FUEL RAIL ASSEMBLY 2 - FUEL RAIL MOUNTING BOLTS 3 - FUEL RAIL CONNECTING HOSES
OPERATION
The intake manifold, meters and delivers air to the combustion chambers allowing the fuel delivered by the fuel injectors to ignite, thus producing power.
DIAGNOSIS AND TESTING—INTAKE MANIFOLD LEAKAGE
An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning.
DR INTAKE MANIFOLD (Continued)
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS, OR THE FAN. DO NOT WEAR LOOSE CLOTHING.
ENGINE - 5.9L
9 - 275
(1) Start the engine. (2) Spray a small stream of water at the suspected
(3) If a change in RPMs occur, the area of the sus-
pected leak has been found.
(4) Repair as required.
leak area.
REMOVAL
(1) Disconnect the negative cable from the battery. (2) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(3) Remove the A/C compressor (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C COMPRESSOR - REMOVAL).
(4) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(5) Remove the accessory drive bracket. (6) Remove the air cleaner. (7) Perform the Fuel System Pressure release pro- cedure (Refer to 14 - FUEL SYSTEM/FUEL DELIV- ERY - STANDARD PROCEDURE). Disconnect the fuel lines (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STAN- DARD PROCEDURE).
(8) Disconnect the accelerator linkage (Refer to 14
- FUEL SYSTEM/FUEL INJECTION/THROTTLE CONTROL CABLE - REMOVAL) and if so equipped, the speed control and transmission kickdown cables.(9) Remove the return spring. (10) Remove the distributor cap and wires. (11) Disconnect the coil wires. (12) Disconnect the heat indicator sending unit
wire.
(13) Disconnect the heater hoses and bypass hose. (14) Remove the closed crankcase ventilation and
evaporation control systems.
(15) Remove intake manifold bolts. (16) Lift the intake manifold and throttle body out
of the engine compartment as an assembly.
(17) Remove and discard the flange side gaskets
and the front and rear end seals.
(18) Remove the throttle body bolts and lift the throttle body off the intake manifold (Fig. 68). Dis- card the gasket.
(19) If required, remove the plenum pan and gas-
ket. Discard gasket.
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Fig.68ThrottleBodyAssembly
1 - FUEL RAIL ASSEMBLY 2 - FUEL RAIL MOUNTING BOLTS 3 - FUEL RAIL CONNECTING HOSES
Clean cylinder block gasket surfaces using a suit-
able solvent.
all foreign material).
The plenum pan rail must be clean and dry (free of
INSPECTION
Inspect manifold for cracks. Inspect mating surfaces of manifold for flatness
with a straightedge.
INSTALLATION
(1) If removed, position new plenum gasket and
install plenum pan (Fig. 69).
(2) Tighten plenum pan mounting bolts as follows: † Step 1. Tighten bolts to 5.4 N·m (48 in. lbs.) † Step 2. Tighten bolts to 9.5 N·m (84 in. lbs.) † Step 3. Check all bolts are at 9.5 N·m (84 in.
lbs.)
(3) Install the flange gaskets. Ensure that the ver- tical port alignment tab is resting on the deck face of the block. Also the horizontal alignment tabs must be in position with the mating cylinder head gasket tabs (Fig. 71). The words MANIFOLD SIDE should be vis- ible on the center of each flange gasket.
(4) Apply Mopart GEN II Silicone Rubber Adhe- sive Sealant, or equivalent, to the four corner joints. An excessive amount of sealant is not required to ensure a leak proof seal. However, an excessive amount of sealant may reduce the effectiveness of the flange gasket. The sealant should be approxi- mately 5 mm (0.2 in) in diameter and 15 mm (0.6 in.) long.
ENGINE - 5.9L
9 - 276
INTAKE MANIFOLD (Continued)DR
Fig.69PlenumPanBoltTighteningSequence (5) Install the front and rear end seals (Fig. 70) Make sure the molded dowel pins on the end seals fully enter the corresponding holes in the cylinder block.
Fig.71IntakeManifoldFlangeGasketAlignment
1 - FLANGE GASKET 2 - ALIGNMENT TABS 3 - CYLINDER HEAD GASKET
follows (Fig. 72):
(8) Install the intake manifold bolts and tighten as † Step 1. Tighten bolts 1 through 4 to 8 N·m (72
in. lbs.) Tighten in alternating steps 1.4 N·m (12 in. lbs.) at a time † Step 2. Tighten bolts 5 through 12 to 8 N·m (72
† Step 3. Check all bolts are torqued to 8 N·m (72
† Step 4. Tighten all bolts in sequence to 16 N·m † Step 5. Check all bolts are torqued to 16 N·m(12 ft. lbs.)
in. lbs.)
in. lbs.)
(12 ft. lbs.)
(9) Install closed crankcase ventilation and evapo-
ration control systems.
(10) Connect the coil wires. (11) Connect the heat indicator sending unit wire. (12) Connect the heater hoses and bypass hose. (13) Install distributor cap and wires. (14) Hook up the return spring. (15) Connect the accelerator linkage (Refer to 14 - FUEL INJECTION/THROTTLE CONTROL CABLE - INSTALLATION) and if so
SYSTEM/FUEL
Fig.70FrontandRearEndSeals
1 - FRONT CROSS-OVER GASKET 2 - REAR CROSS-OVER GASKET
(6) Carefully lower intake manifold into position on the cylinder block and cylinder heads. After intake man- ifold is in place, inspect to make sure seals are in place. (7) Using a new gasket, install the throttle body onto the intake manifold. Tighten the bolts to 23 N·m (200 in. lbs.) torque.
DR INTAKE MANIFOLD (Continued)
ENGINE - 5.9L
9 - 277
Fig.72IntakeManifoldBoltTighteningSequence equipped, the speed control and transmission kick- down cables.
(16) Install the fuel lines (Refer to 14 - FUEL SYS- TEM/FUEL DELIVERY/QUICK CONNECT FIT- TING - STANDARD PROCEDURE).
(17) Install the accessory drive bracket and A/C compressor (Refer to 24 - HEATING & AIR CONDI- TIONING/PLUMBING/A/C INSTALLATION).
COMPRESSOR
(18) 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. (19) Install the air cleaner. (20) Fill cooling system (Refer to 7 - COOLING -STANDARD PROCEDURE).
(21) Connect the negative cable to the battery.
EXHAUST MANIFOLD DESCRIPTION
The exhaust manifolds (Fig. 73) are constructed of cast iron and are LOG type with balanced flow. One exhaust manifold is attached to each cylinder head.
OPERATION
The exhaust manifolds collect the engine exhaust exiting the combustion chambers, then channels the exhaust gases to the exhaust pipes attached to the manifolds.
REMOVAL
(1) Disconnect the negative cable from the battery. (2) Raise and support the vehicle. (3) Remove the bolts and nuts attaching the
exhaust pipe to the engine exhaust manifold.
(4) Lower the vehicle. (5) Remove the exhaust heat shields.
Fig.73ExhaustManifolds—V-8GasEnginesTypical 1 - EXHAUST MANIFOLD (LEFT) 2 - BOLTS & WASHERS 3 - NUTS & WASHERS 4 - EXHAUST MANIFOLD (RIGHT) 5 - BOLTS & WASHERS
(6) Remove bolts, nuts and washers attaching
manifold to cylinder head.
(7) Remove manifold from the cylinder head.
CLEANING
Clean mating surfaces on cylinder head and mani- fold. Wash with solvent and blow dry with com- pressed air.
INSPECTION
Inspect manifold for cracks. Inspect mating surfaces of manifold for flatness with a straight edge. Gasket surfaces must be flat within 0.2 mm per 300 mm (0.008 inch per foot).
INSTALLATION
CAUTION: If the studs came out with the nuts when removing the engine exhaust manifold, install new studs. Apply sealer on the coarse thread ends. Water leaks may develop at the studs if this precau- tion is not taken.
(1) Position the engine exhaust manifolds on the two studs located on the cylinder head. Install coni- cal washers and nuts on these studs (Fig. 74).
(2) Install two bolts and conical washers at the inner ends of the engine exhaust manifold outboard arms. Install two bolts WITHOUT washers on the center arm of engine exhaust manifold (Fig. 74). Starting at the center arm and working outward, tighten the bolts and nuts to 34 N·m (25 ft. lbs.) torque.
(3) Install the exhaust heat shields. (4) Raise and support the vehicle.
ENGINE - 5.9L
9 - 278
EXHAUST MANIFOLD (Continued)DR
(5) Assemble exhaust pipe to manifold and secure with bolts, nuts and retainers. Tighten the bolts and nuts to 34 N·m (25 ft. lbs.) torque.
(6) Lower the vehicle. (7) Connect the negative cable to the battery.
NOTE: Special Tool 6635 must be used to align the front cover and seal with the crankshaft.
(4) Position the special tool 6635 onto the crank-
shaft (Fig. 75).
Fig.74EngineExhaustManifoldInstallation-5.9L
Engines
1 - EXHAUST MANIFOLD (LEFT) 2 - BOLTS & WASHERS 3 - NUTS & WASHERS 4 - EXHAUST MANIFOLD (RIGHT) 5 - BOLTS & WASHERS
TIMING BELT / CHAIN COVER(S) REMOVAL
(1) Disconnect the negative cable from the battery. (2) Remove water pump (Refer to 7 - COOLING/
ENGINE/WATER PUMP - REMOVAL).
(3) Remove power steering pump (Refer to 19 -
STEERING/PUMP - REMOVAL). (4) Remove vibration damper
to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL).
(Refer
(5) Loosen oil pan bolts and remove the front bolt
at each side.
(6) Remove the cover bolts. (7) Remove chain case cover and gasket using
extreme caution to avoid damaging oil pan gasket.
INSTALLATION
(1) Be sure mating surfaces of chain case cover
and cylinder block are clean and free from burrs.
(2) The water pump mounting surface must be
cleaned.
(3) Using a new cover gasket, carefully install chain case cover to avoid damaging oil pan gasket. Use a small amount of Mopart Silicone Rubber Adhe- sive Sealant, or equivalent, at the joint between tim- ing chain cover gasket and the oil pan gasket. Finger tighten the timing chain cover bolts at this time.
Fig.75PositionSpecialTool6635ontoCrankshaft 1 - SPECIAL TOOL 6635
2 - OIL SEAL 3 - TIMING CHAIN COVER(5) Tighten chain case cover bolts to 41 N·m (30
ft.lbs.) torque. Tighten oil pan bolts to 24 N·m (215
in. lbs.) torque.(6) Remove special tool 6635. (7) Inspect the seal flange on the vibration damper. (8) Install vibration damper (Refer to 9 - ENGINE/ ENGINE BLOCK/VIBRATION DAMPER - INSTAL- LATION).
(9) Install water pump and housing assembly using new gaskets (Refer to 7 - COOLING/ENGINE/ WATER PUMP - INSTALLATION).
(10) Install power steering pump (Refer to 19 -
STEERING/PUMP - INSTALLATION).
(11) Install the serpentine belt (Refer to 7 - COOL- ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL- LATION).
(12) Install the cooling system fan (Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLA- TION).
(13) Position the fan shroud and install the bolts.
Tighten the bolts to 11 N·m (95 in. lbs.) torque.
(14) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(15) Connect the negative cable to the battery. (16) Start engine check for leaks.
DR
ENGINE - 5.9L
9 - 279
TIMING BELT/CHAIN AND SPROCKETS REMOVAL
(1) Disconnect battery negative cable. (2) Remove Timing Chain Cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
(3) Re-install
the vibration damper bolt
finger tight. Using a suitable socket and breaker bar, rotate the crankshaft to align timing marks as shown in (Fig. 76).
(4) Remove camshaft sprocket attaching bolt and remove timing chain with crankshaft and camshaft sprockets.
Fig.77MeasuringTimingChainStretch
1 - TORQUE WRENCH 2 - 3.175 MM (0.125 IN.)
imaginary center line through both camshaft and crankshaft bores.
(2) Place timing chain around both sprockets. (3) Turn crankshaft and camshaft to line up with keyway location in crankshaft sprocket and in cam- shaft sprocket.
(4) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(5) Slide both sprockets evenly over their respec- tive shafts and use a straightedge to check alignment of timing marks (Fig. 78).
Fig.78AlignmentofTimingMarks
1 - TIMING MARKS
(6) Install the camshaft bolt. Tighten the bolt to 68
N·m (50 ft. lbs.) torque.
(7) Check camshaft end play. The end play should be 0.051-0.152 mm (0.002-0.006 inch) with a new thrust plate and up to 0.254 mm (0.010 inch) with a used thrust plate. If not within these limits install a new thrust plate.
(8) Install the timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION).
Fig.76AlignmentofTimingMarks
1 - TIMING MARKS
INSPECTION—MEASURING TIMING CHAIN STRETCH
(1) Place a scale next to the timing chain so that
any movement of the chain may be measured.
(2) Place a torque wrench and socket over cam- shaft sprocket attaching bolt. Apply torque in the direction of crankshaft rotation to take up slack; 41
N·m (30 ft. lbs.) torque with cylinder head installed or 20 N·m (15 ft. lbs.) torque with cylinder head removed. With a torque applied to the camshaft sprocket bolt, crankshaft should not be permitted to move. It may be necessary to block the crankshaft to prevent rotation.(3) Hold a scale with dimensional reading even with the edge of a chain link. With cylinder heads installed, apply 14 N·m (30 ft. lbs.) torque in the reverse direction. With the cylinder heads removed, apply 20 N·m (15 ft. lbs.) torque in the reverse direc- tion. Note the amount of chain movement (Fig. 77). if its movement
(4) Install a new timing chain,
exceeds 3.175 mm (1/8 inch).
INSTALLATION
(1) Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact
9 - 280
ENGINE 5.9L DIESEL
ENGINE 5.9L DIESEL
TABLE OF CONTENTS
page
DR
page
ENGINE 5.9L DIESEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 282
DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING—ENGINE
INSPECTION INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . 304
INSTALLATION—CYLINDER HEAD COVER . 304
INSTALLATION—ROCKER HOUSING . . . . . 304DIAGNOSIS - MECHANICAL . . . . . . . . . . . . 283
INTAKE/EXHAUST VALVES & SEATS
DIAGNOSIS AND TESTING—SMOKE
DIAGNOSIS CHARTS . . . . . . . . . . . . . . . . . 285
DIAGNOSIS AND TESTING—CYLINDER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 305
STANDARD PROCEDURESTANDARD PROCEDURE - VALVES,
COMPRESSION/LEAKAGE TESTS . . . . . . . 288
GUIDES AND SPRINGS . . . . . . . . . . . . . . . . 305
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS . . . . . . . . 289
STANDARD PROCEDURE - REPAIR
STANDARD PROCEDURE - VALVE LASH
ADJUSTMENT AND VERIFICATION . . . . . . . 308
REMOVAL - VALVE SPRINGS AND SEALS . . . 308
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 309DAMAGED OR WORN THREADS . . . . . . . . 289
ROCKER ARM / ADJUSTER ASSY
STANDARD PROCEDURE—HYDROSTATIC
LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
REMOVAL
REMOVAL—ENGINE . . . . . . . . . . . . . . . . . . 290
REMOVAL—CRANKCASE BREATHER . . . . 291INSTALLATION
INSTALLATION—ENGINE . . . . . . . . . . . . . . 291
INSTALLATION—CRANKCASE BREATHER . 292SPECIFICATIONS
5.9L DIESEL . . . . . . . . . . . . . . . . . . . . . . . . 293
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . 294SPECIAL TOOLS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 310
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 311
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 312ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER
BLOCK REFACING . . . . . . . . . . . . . . . . . . . 312
STANDARD PROCEDURE - CYLINDER
BORE - DE-GLAZE . . . . . . . . . . . . . . . . . . . 313
STANDARD PROCEDURE—CYLINDER
5.9L DIESEL ENGINE
. . . . . . . . . . . . . . . . . 294
BORE REPAIR . . . . . . . . . . . . . . . . . . . . . . . 313
ENGINE DATA PLATE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 297
AIR CLEANER ELEMENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 298CYLINDER HEAD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 298
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
CLEANINGCLEANING—CYLINDER HEAD . . . . . . . . . . 300
CLEANING—CROSSHEADS . . . . . . . . . . . . 300
. . . . . . . . . . . . . . 301
CLEANING—PUSHRODSINSPECTION
INSPECTION - CYLINDER HEAD . . . . . . . . . 301
INSPECTION—CROSSHEADS . . . . . . . . . . 301
INSPECTION—PUSHRODS . . . . . . . . . . . . . 302
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 302CYLINDER HEAD COVER(S)
REMOVAL
REMOVAL—CYLINDER HEAD COVER . . . . 304
REMOVAL—ROCKER HOUSING . . . . . . . . . 304
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 304STANDARD PROCEDURE—CAM BORE
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
. . . . . . . . . . . . . . . . . . . . . . . . . 316INSPECTION
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVAL—CAMSHAFT BEARINGS . . . . . . 317
REMOVAL - CAMSHAFT . . . . . . . . . . . . . . . 317
. . . . . . . . . . . . . . . . . . . . . . . . . 318INSPECTION INSTALLATION
INSTALLATION - CAMSHAFT BEARINGS . . 320
INSTALLATION - CAMSHAFT . . . . . . . . . . . . 320CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING AND CRANKSHAFT JOURNAL CLEARANCE . . . . . . . . . . . . . . . . 321
CRANKSHAFT AND GEAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 322
REMOVAL—GEAR . . . . . . . . . . . . . . . . . . . . . 322
INSTALLATION - GEAR . . . . . . . . . . . . . . . . . . 322CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - MAIN BEARING
CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . 322
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ENGINE 5.9L DIESEL
9 - 281
CRANKSHAFT OIL SEAL - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 324CRANKSHAFT OIL SEAL - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 325CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 326SOLID LIFTERS/TAPPETS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 328
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 328PISTON & CONNECTING ROD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 329
STANDARD PROCEDURE - HEAD GASKETSELECTION . . . . . . . . . . . . . . . . . . . . . . . . . 330
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
CLEANING—PISTON AND CONNECTINGROD
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
INSPECTION
INSPECTION—PISTONS . . . . . . . . . . . . . . . 331
INSPECTION—CONNECTING ROD . . . . . . . 332
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 332PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 335
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 335FRONT MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 335REAR MOUNT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 337LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 337
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 337
DIAGNOSIS AND TESTING—ENGINE OILPRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 338
OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
STANDARD PROCEDURE - ENGINE OIL
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
OIL COOLER & LINES
CLEANING
CLEANING AND INSPECTION . . . . . . . . . . . 342
OIL FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 342OIL PAN
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 342
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 342OIL PRESSURE RELIEF VALVE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 343
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 343OIL PRESSURE SENSOR/SWITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 343OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 344
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 344INTAKE MANIFOLD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 346
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 346EXHAUST MANIFOLD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 347
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 347VALVE TIMING
STANDARD PROCEDURE - TIMING
VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . 348
GEAR HOUSING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 349GEAR HOUSING COVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 3509 - 282
ENGINE 5.9L DIESEL
ENGINE 5.9L DIESEL DESCRIPTION
DR
The cylinder block is constructed of cast iron. The casting is a skirted design which incorporates longi- tudal ribs for superior strength and noise reduction. The block incorporates metric straight thread o-ring fittings at lubrication oil access points. The engine (Fig. 1) is manufactured with the cylinders being a non-sleeved type cylinder. However, one approved service method is to bore out the cylinders and add cylinder sleeves to the cylinder block.
The cylinders are numbered front to rear (Fig. 2); 1
to 6. The firing order is 1–5–3–6–2–4.
Fig.2CylinderNumbering
Fig.1CumminsT 24-ValveTurbo-DieselEngine
DR ENGINE 5.9L DIESEL (Continued) DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING—ENGINE DIAGNOSIS - MECHANICAL
ENGINE 5.9L DIESEL
9 - 283
CONDITION
POSSIBLE CAUSES
CORRECTION
LUBRICATING OIL PRESSURE LOW
1. Low oil level.
1. (a) Check and fill with clean engine oil.
2. Oil viscosity thin, diluted or wrong specification.
3. Improperly operating pressure switch/gauge. 4. Relief valve stuck open. 6. If cooler was replaced, shipping plugs may have been left in cooler 7. Worn oil pump. 8. Suction tube loose or seal leaking. 9. Loose main bearing cap.
10. Worn bearings or wrong bearings installed.
11. Directed piston cooling nozzles under piston, bad fit into main carrier. 12. Loose oil rifle plug with saddle-jet style nozzles 13. Loose directed piston cooling nozzle. 14. Both J-jet and saddle jet style cooling nozzle installed.
LUBRICATING OIL PRESSURE TOO HIGH
1. Pressure switch/gauge not operating properly. 2. Engine running too cold.
3. Oil viscosity too thick.
4. Oil pressure relief valve stuck closed or binding
(b) Check for a severe external oil leak that could reduce the pressure. 2. (a) Verify the correct engine oil is being used. (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION). 2. (b) Look for reduced viscosity from fuel dilution. 3. Verify the pressure switch is functioning correctly. If not, replace switch/gauge. 4. Check/replace valve. 6. Check/remove shipping plugs.
7. Check and replace oil pump. 8. Check and replace seal. 9. Check and install new bearing. Tighten cap to proper torque. 10. Inspect and replace connecting rod or main bearings. Check and replace directed piston cooling nozzles. 11. Check directed piston cooling nozzles position.
12.Tighten oil rifle plug.
13. Tighten directed piston cooling nozzle.
14. Install correct style jet.
1. Verify pressure switch is functioning correctly. If not, replace switch/gauge. 2. Refer to Coolant Temperature Below Normal (Refer to 7 - COOLING - DIAGNOSIS AND TESTING). 3. Make sure the correct oil is being used. (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION). 4. Check and replace valve.
ENGINE 5.9L DIESEL
9 - 284
ENGINE 5.9L DIESEL (Continued)DR
CONDITION
POSSIBLE CAUSES
CORRECTION
LUBRICATING OIL LOSS
1. External leaks.
2. Crankcase being overfilled.
3. Incorrect oil specification or viscosity.
COMPRESSION KNOCKS
EXCESSIVE VIBRATION
4. Oil cooler leak 5. High blow-by forcing oil out the breather. 6. Turbocharger leaking oil to the air intake. 1. Air in the fuel system.
2. Poor quality fuel or water/gasoline contaminated fuel.
3. Engine overloaded.
4. Improperly operating injectors.
1. Loose or broken engine mounts. 2. Damaged fan or improperly operating accessories. 3. Improperly operating vibration damper 4. Improperly operating electronically controlled viscous fan drive. 5. Worn or damaged generator bearing. 6. Flywheel housing misaligned. 7. Loose or broken power component.
8. Worn or unbalanced driveline components.
EXCESSIVE ENGINE NOISES
1. Drive belt squeal, insufficient tension or abnormally high loading.
2. Intake air or exhaust leaks.
1. Visually inspect for oil leaks. Repair as required. 2. Verify that the correct dipstick is being used. 3. (a) Make sure the correct oil is being used (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION). (b) Look for reduced viscosity from dilution with fuel. (c) Review/reduce oil change intervals. 4. Check and replace the oil cooler. 5. Check the breather tube area for signs of oil loss. Perform the required repairs. 6. Inspect the air ducts for evidence of oil transfer. Repair as required. 1. Identify location of air leak and repair. Do not bleed high pressure fuel system. 2. Verify by operating from a temporary tank with good fuel. Clean and flush the fuel tank. Replace fuel/water separator filter. 3. Verify the engine load rating is not being exceeded. 5. Check and replace misfiring/inoperative injectors.
1. Replace engine mounts. 2. Check and replace the vibrating components. 3. Inspect/replace vibration damper.
4. Inspect/replace fan drive.
5. Check/replace generator.
6. Check/correct flywheel alignment. 7. Inspect the crankshaft and rods for damage that causes an unbalance condition. Repair/replace as required. 8. Check/repair driveline components.
1. Check the automatic tensioner and inspect the drive belt. Make sure water pump, tensioner pulley, fan hub, generator and power steering pump turn freely. 2. Refer to Excessive Exhaust Smoke (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING).
DR ENGINE 5.9L DIESEL (Continued)
ENGINE 5.9L DIESEL
9 - 285
CONDITION
POSSIBLE CAUSES
CORRECTION
3. Excessive valve lash.
4. Turbocharger noise.
5. Gear train noise.
6. Power function knock.
3. Adjust valves. Make sure the push rods are not bent and rocker arms, adjusting screws, crossheads, are not severely worn. Replace bent or severely worn components. 4. Check turbocharger impeller and turbine wheel for housing contact. Repair/replace as required. 5. Visually inspect and measure gear backlash. Replace gears as required. 6. Check/replace rod and main bearings.
DIAGNOSIS AND TESTING—SMOKE DIAGNOSIS CHARTS
The following charts include possible causes and corrections for excess or abnormal exhaust smoke.
Small amounts of exhaust smoke (at certain times) are to be considered normal for a diesel powered engine.
POSSIBLE CAUSE
CORRECTION
EXCESSIVE BLACK SMOKE
Air filter dirty or plugged.
Air intake system restricted.
Air Leak in Intake System.
Diagnostic Trouble Codes (DTC’s) active or multiple,
intermittent DTC’s.
Engine Control Module (ECM) not calibrated or ECM has incorrect calibration. Exhaust system restriction is above specifications.
Fuel grade is not correct or fuel quality is poor.
Fuel injection pump malfunctioning.
Fuel injector malfunctioning.
Fuel return system restricted.
Intake manifold restricted.
Check Filter MinderT at air filter (Refer to 9 - ENGINE/ AIR INTAKE SYSTEM/AIR CLEANER ELEMENT - REMOVAL). Check entire air intake system including all hoses and tubes for restrictions, collapsed parts or damage. Repair/replace as necessary. Check entire air intake system including all hoses and tubes for cracks, loose clamps and/or holes in rubber ducts. Also check intake manifold for loose mounting hardware. Refer to Powertrain Diagnostic Procedures Information.
Refer to Powertrain Diagnostic Procedures Information.
Check exhaust pipes for damage/restrictions. Repair as necessary. Temporarily change fuel brands and note condition. Change brand if necessary. A DTC may have been set. If so, refer to Powertrain Diagnostic Procedures Information. A DTC may have been set. Perform 9Cylinder Cutout Test9 using DRB scan tool to isolate individual cylinders. Also refer to Powertrain Diagnostic Procedures Information and, to (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - DIAGNOSIS AND TESTING). Check fuel return lines for restriction (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - DIAGNOSIS AND TESTING). Remove restriction.
ENGINE 5.9L DIESEL
9 - 286
ENGINE 5.9L DIESEL (Continued)DR
POSSIBLE CAUSE
CORRECTION
EXCESSIVE BLACK SMOKE
Manifold Air Pressure (Boost) Sensor or sensor circuit malfunctioning. Raw fuel in intake manifold.
Turbocharger air intake restriction. Turbocharger damaged.
Turbocharger has excess build up on compressor wheel and/or diffuser vanes. Turbocharger wheel clearance out of specification.
A DTC should have been set. Refer to Powertrain Diagnostic Procedures Information. Fuel injectors leaking on engine shutdown. Do Fuel Injector Test (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - DIAGNOSIS AND TESTING). Remove restriction. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM/TURBOCHARGER - INSPECTION). (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM/TURBOCHARGER - CLEANING). (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM/TURBOCHARGER - INSPECTION).
POSSIBLE CAUSE
CORRECTION
EXCESSIVE WHITE SMOKE
Air in fuel supply: Possible leak in fuel supply side (between transfer pump and fuel tank module). Coolant leaking into combustion chamber.
Diagnostic Trouble Codes (DTC’s) active or multiple, intermittent DTC’s. In very cold ambient temperatures, engine block heater is malfunctioning (if equipped). Engine coolant temperature sensor malfunctioning.
Engine Control Module (ECM) not calibrated or has incorrect calibration. Fuel filter plugged.
Fuel grade not correct or fuel quality is poor.
Fuel heater element or fuel heater temperature sensor malfunctioning. This will cause wax type build-up in fuel filter. Fuel injector malfunctioning.
Fuel injector hold-downs loose.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL TRANSFER PUMP - DIAGNOSIS AND TESTING). Do pressure test of cooling system (Refer to 7 - COOLING - DIAGNOSIS AND TESTING). Refer to Powertrain Diagnostic Procedures Information.
(Refer to 7 - COOLING/ENGINE/ENGINE BLOCK HEATER - REMOVAL). A DTC should have been set. Refer to Powertrain Diagnostic Procedures Information. Also check thermostat operation (Refer to 7 - COOLING/ENGINE/ ENGINE COOLANT THERMOSTAT - DIAGNOSIS AND TESTING). A DTC should have been set. Refer to Powertrain Diagnostic Procedures Information. Refer to Powertrain Diagnostic Manual for fuel system testing. Temporarily change fuel brands and note condition. Change brand if necessary. Refer to Fuel Heater Testing (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL HEATER - DIAGNOSIS AND TESTING). A DTC should have been set. Perform 9Cylinder cutout Test9 using DRB scan tool to isolate individual cylinders. Also refer to Powertrain Diagnostic Procedures Information and, (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - DIAGNOSIS AND TESTING). Torque to specifications.
DR ENGINE 5.9L DIESEL (Continued)
ENGINE 5.9L DIESEL
9 - 287
EXCESSIVE WHITE SMOKE
POSSIBLE CAUSE
Fuel injector protrusion not correct.
Fuel injection pump malfunctioning.
Fuel supply side restriction to transfer pump.
Fuel transfer (lift) pump malfunctioning.
Intake/Exhaust valve adjustments not correct (too tight).
Intake manifold air temperature sensor malfunctioning.
Intake manifold heater circuit not functioning correctly in cold weather.
Intake manifold heater elements not functioning correctly in cold weather.
Internal engine damage (scuffed cylinder).
Restriction in fuel supply side of fuel system.
CORRECTION
Check washer (shim) at bottom of fuel injector for correct thickness. (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - INSTALLATION) A DTC should have been set. Refer to Powertrain Diagnostic Procedures Information. Refer to Powertrain Diagnostic Manual for fuel system testing. A DTC may have been set. Refer to Powertrain Diagnostic Procedures Information. (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/ EXHAUST VALVES & SEATS - STANDARD PROCEDURE). A DTC should have been set. Refer to Powertrain Diagnostic Procedures Information. A DTC should have been set. Refer to Powertrain Diagnostic Procedures Information. Also check heater elements for correct operation. A DTC should have been set if heater elements are malfunctioning. Refer to Powertrain Diagnostic Procedures Information. Analyze engine oil and inspect oil filter to locate area of probable damage. Refer to Powertrain Diagnostic Manual for fuel system testing.
POSSIBLE CAUSE
CORRECTION
EXCESSIVE BLUE SMOKE
Dirty air cleaner or restricted turbocharger intake duct.
Air leak in boost system between turbocharger compressor outlet and intake manifold. Obstruction in exhaust manifold.
Restricted turbocharger drain tube.
Crankcase ventilation system plugged. Valve seals are worn, brittle, or improperly installed.
Valve stems and/or guides are worn.
Broken or Improperly installed piston rings.
Check Filter MinderT at air filter housing. (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER ELEMENT - REMOVAL). Service air charge system..
Remove exhaust manifold and inspect for blockage (Refer to 9 - ENGINE/MANIFOLDS/EXHAUST MANIFOLD - REMOVAL). Remove turbocharger drain tube and remove obstruction. Inspect crankcase ventilation system for function Replace valve stem oil seals (Refer to 9 - ENGINE/ CYLINDER HEAD/INTAKE/EXHAUST VALVES & SEATS - REMOVAL). Remove valves and inspect valves and guides. (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST VALVES & SEATS - STANDARD PROCEDURE). Tear down engine and inspect piston rings.
ENGINE 5.9L DIESEL
9 - 288
ENGINE 5.9L DIESEL (Continued)EXCESSIVE BLUE SMOKE
DR
POSSIBLE CAUSE
Excessive piston ring end gap.
Excessive cylinder bore wear and taper.
Cylinder damage.
Piston damage.
Turbocharger failure.
DIAGNOSIS AND TESTING—CYLINDER COMPRESSION/LEAKAGE TESTS
CYLINDER COMPRESSION PRESSURE
The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunc- tions.
Ensure batteries are completely charged and the engine starter motor is in good operating condition. Otherwise, the indicated compression pressures may not be valid for diagnostic purposes.
(1) Disconnect the fuel inlet line to the fuel trans-
fer pump. Plug the fuel line from the fuel tank.
(2) Start the engine and idle until the engine stalls
(runs out of fuel).
(3) Disconnect all three injector wire harness con-
nectors at the rocker housing.
(4) Remove the breather cover and cylinder head
cover.
(5) Remove the high pressure fuel line between the cylinder head and fuel rail for the cylinder to be tested.
(6) Remove the exhaust rocker lever. (7) Use Tool 9010 to remove the injector and cop-
per sealing washer.
43 N·m (32 ft. lbs.).
(8) Install the exhaust rocker lever and torque to
(9) Cover the remaining rocker levers with clean shop towels to prevent any oil splatter under the hood.
(10) Place a rag over the compression test tool fit- ting. Crank the engine for 2–3 seconds to purge any fuel that may have drained into the cylinder when the injector was removed.
CORRECTION
Remove pistons and measure piston ring end gap (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON RINGS - STANDARD PROCEDURE). Remove pistons and measure cylinder bore wear and taper (Refer to 9 - ENGINE/ENGINE BLOCK - STANDARD PROCEDURE). Remove pistons and inspect cylinder bore for cracks or porosity. Repair with cylinder liner if necessary. (Refer to 9 - ENGINE/ENGINE BLOCK - STANDARD PROCEDURE). Remove pistons and inspect for cracks, holes. Measure piston for out-of-round and taper (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON & CONNECTING ROD - INSPECTION). (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM/TURBOCHARGER - INSPECTION).
(11) Connect the compression test gauge. (12) Crank the engine for 5 seconds and record the pressure reading. Repeat this step three times and calculate the average of the three readings.
(13) Combustion pressure leakage can be checked if cylinder pressure is below the specification. Per- form the leakage test procedure on each cylinder according to the tester manufacturer instructions.
(14) Upon completion of the test check an erase
any engine related fault codes.
CYLINDER COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition. Combustion pressure leakage testing will detect: † Exhaust and intake valve leaks (improper seat- ing).† Leaks between adjacent cylinders or into water jacket.† Any causes for combustion/compression pressure loss (1) Start and operate the engine until it attains
normal operating temperature.
(2) Remove the breather cover and cylinder head
cover.
(3) Disconnect all three injector wire harness con-
nectors at the rocker housing.
(4) Bring the cylinder to be tested to TDC. (5) Remove the high pressure fuel line between the cylinder head and the fuel rail for the cylinder to be tested.
(6) Install capping Tool 9011 onto the rail. (7) Remove the high pressure connector nut and
high pressure connector with Tool 9015.
(8) Remove the exhaust and intake rocker lever.
DR ENGINE 5.9L DIESEL (Continued)
(9) Use Tool 9010 to remove the injector and cop-
per sealing washer.
injector bore.
(10) Install compression test Tool 9007 into the
(11) Connect the leakage tester and perform the leakage test procedure on each cylinder according to the tester manufacturer’s instructions.
(12) Upon completion of the test check and erase
any engine related fault codes.
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-PLACE GASKETS AND SEALERS
There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results. Do not use form-in- place gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket materials that are used in the engine area. Mopart Engine RTV GEN II, Mopart ATF-RTV, and Mopart Gasket Maker gasket materials, each have different properties and can not be used in place of the other.
MOPARt ENGINE RTV GEN II Mopart Engine RTV GEN II is used to seal com- ponents exposed to engine oil. This material is a spe- cially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.
MOPARt ATF RTV Mopart ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and seal- ing properties to seal components exposed to auto- matic coolants, and moisture. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use.
transmission fluid,
engine
MOPARt GASKET MAKER Mopart Gasket Maker is an anaerobic type gasket material. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic
ENGINE 5.9L DIESEL
9 - 289
material is for use between two machined surfaces. Do not use on flexible metal flanges.
MOPARt GASKET SEALANT Mopart Gasket Sealant is a slow drying, perma- nently soft sealer. This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts under all temperatures. This mate- rial is used on engines with multi-layer steel (MLS) cylinder head gaskets. This material also will pre- vent corrosion. Mopart Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER APPLICATION
Assembling parts using a form-in-place gasket requires care but it’s easier than using precut gas- kets.
Mopart Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant to one gasket surface. Be certain the material sur- rounds each mounting hole. Excess material can eas- ily be wiped off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during assembly to prevent smear- ing material off the location.
Mopart Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 3 mm (0.120 in.) in diameter. All mounting holes must be circled. For corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towel. Components should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to prevent smearing material off the location.
Mopart Gasket Sealant in an aerosol can should be applied using a thin, even coat sprayed completely over both surfaces to be joined, and both sides of a gasket. Then proceed with assembly. Material in a can w/applicator can be brushed on evenly over the sealing surfaces. Material in an aerosol can should be used on engines with multi-layer steel gaskets.
STANDARD PROCEDURE - REPAIR DAMAGED OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain the original center line.
tially, this repair consists of:
Damaged or worn threads can be repaired. Essen- † Drilling out worn or damaged threads. † Tapping the hole with a special Heli-Coil Tap, or
equivalent.
ENGINE 5.9L DIESEL
9 - 290
ENGINE 5.9L DIESEL (Continued) † Installing an insert into the tapped hole to bring the hole back to its original thread size.STANDARD PROCEDURE—HYDROSTATIC LOCK
