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CAUTION: DO NOT use the starter motor to rotate the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock (regardless of what caused the problem), follow the steps below.
(1) Disconnect the negative cable(s) from the bat-
oil.
tery.
(2) Inspect air
induction system, and intake manifold to ensure system is dry and clear of foreign material.
cleaner,
(3) Place a shop towel around the fuel injectors to catch any fluid that may possibly be under pressure in the cylinder head. Remove the fuel injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - REMOVAL).
(4) With all injectors removed, rotate the crank- shaft using the crankshaft barring tool (PN 7471–B). (5) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
cylinders.
(6) Be sure all fluid has been removed from the
extension pipe.
(7) Repair engine or components as necessary to
connectors.
prevent this problem from occurring again.
(8) Squirt a small amount of engine oil into the cylinders to lubricate the walls. This will prevent damage on restart.
(9) Install fuel injectors (Refer to 14 - FUEL SYS-
INJECTION/FUEL
INJECTOR
TEM/FUEL INSTALLATION).
(10) Drain engine oil. Remove and discard the oil filter (Refer to 9 - ENGINE/LUBRICATION/OIL FIL- TER - REMOVAL).
(11) Install the drain plug. Tighten the plug to 50
N·m (37 ft. lbs.) torque.
(12) Install a new oil filter (Refer to 9 - ENGINE/
LUBRICATION/OIL FILTER - INSTALLATION).
(13) Fill engine crankcase with the specified amount and grade of oil (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES SPECIFICA- TIONS).
(14) Connect the negative cable(s) to the battery. (15) Start the engine and check for any leaks.
REMOVAL
REMOVAL—ENGINE
(1) Disconnect both battery negative cables. (2) Disconnect engine grid heater harness at grid
heater relays.
DR
(3) Disconnect electrical connections from rear of
alternator.
(4) Recover A/C refrigerant. (Refer to 24 - HEAT- ING & AIR CONDITIONING/PLUMBING - STAN- DARD PROCEDURE).
(5) Raise vehicle on a hoist. (6) Drain engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(7) Remove engine oil drain plug and drain engine
(8) Remove fan/drive assembly. Refer to Section 7
– Fan/Drive Removal
(9) Remove radiator upper hose. (10) Remove upper fan shroud mounting bolts. (11) Disconnect the coolant recovery bottle hose
from the radiator fill neck and remove bottle.
(12) Using a 36mm wrench, remove viscous fan/ drive assembly. (Refer to 7 - COOLING/ENGINE/RA- DIATOR FAN - REMOVAL).
(13) Remove cooling fan and shroud together. (14) Disconnect heater core supply and return hoses from the cylinder head fitting and coolant pipe.
(15) Raise vehicle on a hoist. (16) Remove transmission and transfer case (if
equipped).
(17) Disconnect exhaust pipe from turbocharger
(18) Disconnect engine harness to vehicle harness
(19) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).
(20) Remove flywheel/flexplate. (21) Remove transmission adapter (22) Disconnect A/C suction/discharge hose from
the rear of the A/C compressor.
(23) Lower vehicle. (24) Disconnect lower radiator hose from radiator
outlet.
(25) Automatic transmission models: (26) Disconnect transmission oil cooler lines from
in front of radiator using special tool #6931
(27) Remove radiator. (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(28) If A/C equipped, disconnect A/C condenser
refrigerant lines.
(29) Disconnect charge air cooler piping. (30) Remove charge air cooler mounting bolts. (31) Remove charge air cooler (and A/C condenser
if equipped) from vehicle.
(32) Remove damper and speed indicator ring from
front of engine.
(33) Disconnect engine block heater connector. (34) Disconnect A/C compressor and pressure sen-
sor electrical connectors.
DR ENGINE 5.9L DIESEL (Continued)
ENGINE 5.9L DIESEL
9 - 291
(51) Loosen but do not remove engine mount
through bolts and nuts.
(52) Disconnect hood support struts and position
hood out of the way.
lift brackets.
out of the mounts.
chassis.
(53) Attach a chain with two hooks to the engine
(54) While keeping engine level, lift straight up
(55) Rotate nose of engine upward and pull out of
REMOVAL—CRANKCASE BREATHER
(1) Remove the oil fill cap. (2) Remove the breather cover bolts (Fig. 4). (3) Remove breather cover. (4) Disconnect breather tube and lube oil drain
tube from breather.
(5) Remove breather mounting bolts. (6) Remove breather from cylinder head cover.
(35) Remove the passenger battery ground cable from the engine block. Remove the driver side bat- tery ground cable from the engine block.
(36) Remove power steering pump from engine by
removing 3 bolts.
(37) Remove accelerator linkage cover. (38) Disconnect cables from APPS if early model build (39) If late model build, (40) Disconnect the ECM power connector. (41) Disconnect the ECM ground wire from the
hydroform screw.
(42) Disconnect the fuel supply and return hoses. (43) Remove the cylinder head cover. (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(44) Disconnect the 3 injector harness connectors at the rocker housing. Disconnect the wire harnesses from the injectors.
(45) Remove the rear engine lift bracket. (46) Remove cylinder #4, #5, and #6 intake and exhaust rocker arms, pedestals, and push tubes. Note the original location for re-assembly.
line shield bolts and rotate
(47) Loosen #6 fuel shield out of the way.
(48) Remove cylinder #5 and #6 high pressure fuel lines. Remove the fuel connector tube nut and fuel con- nector tube. 46. Remove cylinder #5 and #6 fuel injector.
(49) Remove rocker housing. (50) Remove two cylinder head bolts in location 4
and 12 according to the diagram below and install Tool # 9009 (Fig. 3).Fig.4CrankcaseBreatherVaporCanister
1 - BREATHER COVER BOLT 2 - BREATHER COVER 3 - BREATHER TUBE 4 - ROCKER COVER 5 - BREATHER TUBE MOUNTING BRACKET 6 - LUBE OIL DRAIN TUBE 7 - O-RING 8 - BREATHER 9- BREATHER MOUNTING BOLT
INSTALLATION
INSTALLATION—ENGINE
(1) Remove cylinder head bolts in locations 4 and 12 according to the diagram below. Install special Tool 9009.
Fig.3ENGINELIFTBRACKET
1 - Head bolt 2 - Engine Lift Bracket 3 - Head Bolt
ENGINE 5.9L DIESEL
9 - 292
ENGINE 5.9L DIESEL (Continued)DR
(2) Lower engine into the engine compartment and install the engine the engine mount through bolts and nuts.
(3) Tighten the mount through bolts and nuts to
88 N-m (65 ft-lbs) torque.
(4) Remove the engine lifting device (Tool 9009). (5) Check cylinder head capscrew length and
install into cylinder head.
(6) Torque alternately to 70 N-m (52 ft-lbs). Torque alternately to 105 N-m (77 ft-lbs). Rotate 90 degrees. (7) Install rocker housing. Torque to 24 N-m (18 ft- lbs). Refer to Section 9 Rocker Housing Installation (8) Replace injector o-ring and sealing washer on injectors #5 and #6. Install injectors and alternately tighten hold-down capscrews to 10 N-m (89 in-lbs).
(9) Install fuel connector tube and fuel connector
tube nut. Torque to 50 N-m (37 ft-lb). 10.
(10) Install #5 and #6 high pressure fuel lines. Fol- low correct torque sequence per section 14. Torque fuel line fittings to 30 N-m (22 ft-lb). Torque brace capscrew to 24 N-m (18 ft-lb).
(11) Install rear engine lift bracket. Torque to 77
N-m (57 ft-lb).
(12) Install push tubes, rocker arms, and pedestals for cylinders #4, #5, and #6. Torque the mounting bolts to 36 N-m (27 ft-lbs).
(13) Reset valve lash on cylinders #4, #5, and #6.
Torque adjusting nuts to 24 N-m (18 ft-lbs).
(14) Install cylinder head cover. Torque to 24 N-m (18 ft-lbs).(Refer to 9 - ENGINE/CYLINDER HEAD - INSTALLATION).
(15) Connect breather tube and lube oil drain tube to breather housing. Install breather housing. Torque capscrews to 24 N-m (18 ft-lbs)
(16) Connect fuel supply and return hoses. (17) Connect ECM ground to hydroform screw.
Connect ECM power connector.
the throttle linkage cover.
(19) Install the power steering pump. (20) Install the damper and speed indicator ring.
Torque to 40 N-m (30 ft-lb) plus 60 degrees.
(21) Connect the engine block heater connection. (22) Connect the A/C compressor and pressure sen-
sor connectors
(23) Install the charge air cooler and a/c condenser (if equipped). Install and tighten the charge air cooler mounting bolts to 2 N-m (17 in-lbs).
(24) Connect the charge air cooler piping. Torque
all clamps to 8 N-m (72 in-lbs).
(25) Connect the a/c refrigerant lines to the a/c
condenser (if equipped).
(26) Install the radiator upper support panel. (27) Install radiator. (28) Connect the transmission quick-connect oil
cooler lines.
(29) Raise vehicle. (30) Connect a/c compressor suction/discharge hose
(if equipped).
(31) Install the radiator lower hose and clamps. (32) Install
the battery negative cables to the
engine block on the driver and passenger side.
(33) Install the transmission adapter with a new camshaft rectangular ring seal. Torque to 77 N-m (57
ft-lb).(34) Install the flywheel/flexplate. Torque to 137
N-m (101 ft-lb).
(35) Install the starter motor. Torque to 43 N-m (32 ft-lb). (Refer to 8 - ELECTRICAL/STARTING/ STARTER MOTOR - INSTALLATION).
(36) Connect engine to vehicle harness connectors. (37) Install transmission and transfer case (if
equipped).
elbow.
(38) Connect the exhaust pipe to the turbocharger
(39) Connect the transmission auxiliary oil cooler
lines (if equipped).
(40) Lower the vehicle. (41) Connect the heater core supply and return hoses. (42) Install the cooling fan and upper fan shroud at the same time. (Refer to 7 - COOLING/ENGINE/ RADIATOR FAN - INSTALLATION).
(43) Install the coolant recovery bottle. (44) Install the windshield washer bottle. (45) Install the upper radiator hose and clamps. (46) Raise vehicle. (47) Connect electronically controlled fan drive
wire harness. Install lower radiator fan shroud.
(48) Change oil filter and install new engine oil. (49) Fill the cooling system with coolant. (Refer to
7 - COOLING - STANDARD PROCEDURE).
(50) Connect grid heater harness at grid heater
relays.
nator.
(52) Start the engine and inspect for engine oil,
coolant, and fuel leaks.
INSTALLATION—CRANKCASE BREATHER
(1) Install a new o-ring onto the breather element. (2) Lubricate o-ring and install into cylinder head
cover. Torque capscrews to 10 N·m (89 in. lbs.).
(3) Connect breather tube and lube oil drain tube. (4) Install breather cover (Fig. 4). Torque to 24
N·m (18 ft. lbs.)
(5) Install oil fill cap.
(18) Install the APPS cable(s) to the APPS. Install
(51) Connect electrical connections to rear of alter-
DR ENGINE 5.9L DIESEL (Continued) SPECIFICATIONS
5.9L DIESEL
DESCRIPTION
Engine Type
Bore and Stroke
Displacement
Compression Ratio
305/250/235 H.P. Version Horsepower (A/T and 5
Speed M/T)
SPECIFICATION
In-Line 6 Cyl. Turbo
Diesel
102.0 X 120.0 mm (4.02 X 4.72 in.) 5.9L (359 cu. in.)
17.2:1
235 @ 2700 rpm
(CARB)
250 @2900 rpm (49
State)
Horsepower (6 Speed M/T
305 @ 2900 rpm
Only)
Torque Rating (A/T and 5
460 ft. lbs. @ 1400 rpm
Speed M/T)
Torque Rating (6 Speed
555 ft. lbs. @ 1400 rpm
M/T Only) Firing Order
1-5-3-6-2-4
ENGINE 5.9L DIESEL
9 - 293
DESCRIPTION
Piston Pins
SPECIFICATION
Pin Diameter (Min.)
39.990 mm (1.5744
inch)
(Max)
40.003 mm (1.5749 in.)
Bore Diameter (Min)
40.006 mm (1.5750
inch.
(Max)
40.012 mm (1.5753 in.)
Piston Ring End Gap
Top Ring
Intermediate
Oil Control
Connecting Rods
0.26 – 0.36 mm
(0.010 – 0.014 in.)
0.85 – 1.15 mm (0.33 – 0.045 in.) 0.25 – 0.55 mm
(0.010 – 0.021 in.)
Pin Bore Diameter (Max.
w/busing installed)
40.019 mm – 40.042
mm (1.5764 – 1.5765Side Clearance
in.)
0.100 – 0.330 mm (0.004 – 0.013 in.)
Lubrication System
Pressure Feed-Full Flow
CYLINDER HEAD
Cylinder Block
Crankshaft
Cylinder Head
Combustion Chambers
Camshaft Pistons
With Bypass Valve
Cast Iron
Induction Hardened
Forged Steel
Cast Iron With Valve
Seat Inserts
High Swirl Bowl
Chilled Ductile Iron
Cast Aluminum
Overall Flatness End to
0.305 mm (0.012 in.)
End (Max.)
Overall Flatness Side to
0.076 mm (0.003 in.)
Side (Max.)
Intake Valve Seat Angle Exhaust Valve Seat Angle
Valve Stem Diameter
(Min) (Max)
30° 45°
6.96 mm (0.2740 in.) 7.01 mm (0.2760 in.) 0.79 mm (0.031 in.)
Connecting Rods
Cross Rolled Micro Alloy
PISTONS AND CONNECTING RODS
Valve Rim Thickness
(Min.)
Piston
Skirt Diameter
101.864 – 101.887 mm
Ring Groove Clearance
Intermediate (Min.)
(Max)
Oil Control (Min)
(Max)
(4.010 – 4.011 in.)
0.045 mm (.0018 inch) 0.095 mm (0.0037 inch) 0.040 mm (.0016 inch) 0.085 mm (0.0033 inch)
OIL PRESSURE
At Idle
At 2,500 rpm
Regulating Valve Opening
Pressure
69 kPa (10 psi) 207 kPa (30 psi) 517 kPa (75 psi)
Oil Filter Bypass Pressure
344.75 kPa (50 psi)
Setting
ENGINE 5.9L DIESEL
9 - 294
ENGINE 5.9L DIESEL (Continued) TORQUETORQUE CHART 5.9L DIESEL ENGINE
DR
SPECIAL TOOLS
5.9L DIESEL ENGINE
DESCRIPTION
N·m
In. Lbs.
Ft. Lbs.
Connecting Rod—Bolts
Step 1
Step 2
Step 3— —
30
22
60
44
Rotate 60 degreesCrankshaft Main Cap—Bolts
50
80Step 1
Step 2
Step 3Rotate 90°
37
59Cylinder Head—Bolts
UniversalDriverHandle-C4171
—
70
52
Step 1
Step 2 Back off 360 degrees Step 3
Step 4 Verify Step 577
105
105
77
Rotate All Bolts 1/4— —
Cylinder Head Cover Bolts Breather Cover Bolts HPC Nut Fuel Delivery Lines—Banjo Fuel Drain Line—Banjo Fuel line—rail to cylinder head Fuel line—pump to fuel rail Injector fuel line brace Fuel rail holddown bolt Oil Pan—Bolts Oil Pan—Drain Plug Oil Pressure Regulator—Plug Oil Pressure Switch
Oil Pump—Bolts Step1
Step2Oil Suction Tube (Flange)— Bolts Oil Suction Tube (Brace)— Bolt Rocker Arm/Pedestal—Bolts
24
24
50
24
2430
30
24
24
28
50
80
1824
24
43
36
Turn — —
— —
—
— —
— — — —
— —
—
—
—
18
18
37
18
1822
22
18
18
21
37
60
1318
18
32
27
CrankshaftBarringTool-7471-B
CrankshaftFrontOilSealInstaller-8281
ValveSpringCompressor-8319A
TestPlug-8442
DR ENGINE 5.9L DIESEL (Continued)
ENGINE 5.9L DIESEL
9 - 295
Adapter-8462
CompressionTestAdapter-9007
EngineSupportFixture-8534
EngineLiftBracket-9009
TAPPETINSTALLATIONTOOL-8502
FuelInjectorRemover-9010
STEELBRACKET-8534-A
ENGINE 5.9L DIESEL
9 - 296
ENGINE 5.9L DIESEL (Continued)DR
FUELBLOCKOFFPLUG-9011
FuelInjectorTube(Connector)Remover-9015
FUELTESTFITTING-9013
TURBOTESTADAPTER-9022
DR
ENGINE 5.9L DIESEL
9 - 297
has experienced. A drop in air pressure due to an air cleaner element restriction moves diaphragm and yellow disc will indicate size of air drop.
CAUTION: Certain engine degreasers or cleaners may discolor or damage plastic housing of Filter Minder. Cover and tape Filter Minder if any engine degreasers or cleaners are to be used.
To test, turn engine off. If yellow disc (Fig. 7) has reached red colored zone on graduated scale, air cleaner element should be replaced. Refer to Removal / Instal- lation.
Resetting Filter Minder: After air cleaner (filter) element has been replaced, press rubber button on top of Filter Minder (Fig. 7). This will allow yellow colored disc to reset. After button has been pressed, yellow disc should spring back to UP position.
If Filter Minder gauge has reached red colored zone, and after an examination of air cleaner (filter) element, element appears to be clean, high reading may be due to a temporary condition such as snow build-up at air intake. Temporary high restrictions may also occur if air cleaner (filter) element has got- ten wet such as during a heavy rain or snow. If this occurs, allow element to dry out during normal engine operation. Reset rubber button on top of Filter Minder and retest after element has dried.
ENGINE DATA PLATE DESCRIPTION
The engine data plate contains specific information that is helpful to servicing and obtaining parts for the engine. The data plate can be found in two places. Some models have a data plate is located on the left side of the engine, affixed to the APPS bracket. Some models will have the data plate affixed to the breather cover on the left side of the engine. Information that can be found on the data plate includes: † Date of Engine Manufacture † Engine Serial Number † Control Parts List (CPL) † Engine Rated Horsepower † Engine Firing Order † Engine Displacement † Valve Lash Reset Specifications If the engine data plate is missing or not legible, the engine serial number is used for engine identifi- cation. The engine serial number is stamped on the right side of the block, on top of the oil cooler cavity (Fig. 5).
Fig.5EngineSerialNumberLocation
AIR CLEANER ELEMENT REMOVAL
Testing Air Cleaner Element using Filter Minder™
Do not attempt to unnecessarily remove top of air cleaner housing for air cleaner element inspection on diesel engines.
The air cleaner (filter) housing is equipped with an air Filter Minder™ gauge (Fig. 6). This air flow restriction gauge will determine when air cleaner ele- ment is restricted and should be replaced.
The Filter Minder™ consists of a diaphragm and calibrated spring sealed inside of a plastic housing (Fig. 7). A yellow colored disc attached to diaphragm moves along a graduated scale on side of Filter Minder. After engine has been shut off, a ratcheting device located within Filter Minder will hold yellow disc at highest restriction that air cleaner element
Fig.65.9LDIESELAIRCLEANER-FILTER
MINDER™
1 - CLIPS 2 - FILTER COVER 3 - FILTER MINDER™ 4 - INLET AIR TEMPERATURE/ PRESSURE SENSOR 5 - FILTER HOUSING
ENGINE 5.9L DIESEL
9 - 298
AIR CLEANER ELEMENT (Continued)REMOVAL
DR
(1) Disconnect battery negative cables. (2) Raise vehicle on hoist. (3) Drain engine coolant. (4) Disconnect exhaust pipe from turbocharger
(5) Lower vehicle. (6) Disconnect air inlet temperature/pressure sen-
elbow.
sor.
(7) Remove air cleaner housing and snorkel from the vehicle. Cap off turbocharger air inlet to prevent intrusion of dirt or foreign material.
(8) Disconnect cab heater core supply and return
hoses from the cylinder head and heater pipe.
(9) Disconnect turbocharger oil drain tube at rub- ber hose connection. Cap off open ports to prevent intrusion of dirt or foreign material.
(10) Disconnect turbocharger oil supply line at the turbocharger end. Cap off open ports to prevent intrusion of dirt or foreign material.
(11) Remove exhaust manifold-to-cylinder head bolts, spacers, heat shield, retention straps, and cab heater plumbing. Remove exhaust manifold and tur- bocharger from the vehicle as an assembly.
(12) Remove cooling fan assembly. (13) Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(14) Remove cooling fan support
from cylinder
block.
(15) Remove upper generator bolt,
loosen lower generator bolt, and rotate generator away from cylin- der head.
(16) Disconnect radiator upper hose from the ther-
mostat housing.
(17) Disconnect the Intake Air Temperature, Man- ifold Air Pressure, and Coolant Temperature sensor connector.
(18) Remove the engine harness to cylinder head
attaching bolts and P-clips at front of head.
(19) Remove the throttle linkage cover (Fig. 8). (20) Remove the six (6) accelerator pedal position sensor assembly-to-cylinder head bracket bolts (Fig. 9) and secure the entire assembly out of the way. Disconnect the APPS connector (Fig. 10). It is not necessary to disconnect the cables from the throttle control assembly.
(21) Remove the intake air grid heater wires from
the grid heater.
(22) Remove engine oil level indicator tube attach- ing bolt at fuel filter housing bracket and inlet air connection..
(23) Remove the charge air cooler-to-air inlet hous-
ing pipe.
Fig.7FILTERMINDER™-5.9LDIESEL
1 - PRESS BUTTON TO RESET 2 - YELLOW DISC 3 - RED ZONE 4 - TO AIR FILTER HOUSING 5 - FILTER MINDER
Filter Removal
(1) The housing cover is equipped with spring clips (Fig. 6) and is hinged with plastic tabs. Unlatch clips from top of air cleaner housing and tilt housing cover up for cover removal.
(2) Remove air cleaner element from air cleaner
housing.
INSTALLATION
(1) Before installing new air cleaner element (fil-
ter), clean inside of air cleaner housing.
(2) Position air cleaner cover to tabs on front of air cleaner housing. Latch spring clips to seal cover to housing.
CYLINDER HEAD DESCRIPTION
The cylinder head is constructed of cast iron and is a one piece cross flow design with four valves per cyl- inder. The arrangement of two intake and two exhaust valves per cylinder allows for a centrally located injector. The cylinder head also includes an integral thermostat housing, and a longitudal fuel return rifle, which exits at the rear of the head. The 24 valve design also includes integrally cast valve guides and hard- ened intake and exhaust valve seat inserts.
intake manifold, an integral
DR CYLINDER HEAD (Continued)
ENGINE 5.9L DIESEL
9 - 299
Fig.8ThrottleLinkageCover
Fig.10APPSConnector
1 - CABLE/LEVER/LINKAGE COVER 2 - PUSH UP LOWER TAB 3 - SCREWS/CLIPS (2) 4 - TAB PUSH HERE
1 - APPS 2 - TAB 3 - PUSH FOR REMOVAL 4 - APPS CONNECTOR
(27) Remove the engine lift bracket from the rear
of the cylinder head.
(28) Remove the high pressure pump to fuel
rail fuel line as follows:
(a) Loosen fuel line nuts at fuel pump and at
fuel rail.
(b) Use a back-up wrench on the fitting at the
fuel pump to keep it from loosening. (29) Remove the fuel rail to cylinder head fuel
lines as follows:
(a) Loosen No. 6 high pressure fuel line shield
and position out of way.
(b) Loosen the fuel line nuts at the fuel rail and
at the cylinder head.
(c) Remove the fuel intake manifold cover. (30) Remove the fuel rail as follows:
line bracket bolts at the
(a) Remove fuel rail pressure sensor connector. (b) Remove banjo fitting at pressure limiting
valve.
(c) Remove fuel rail bolts and fuel rail.
(31) Remove the low pressure lines as follows:
(a) Remove the fuel drain banjo fitting on the
front side of fuel filter housing.
(b) Remove the fuel drain banjo fitting on rear
side of fuel filter housing.
(c) Remove the fuel drain line support bracket
on rear side of filter housing. (d) Remove fuel drain hose.
Fig.9APPSAssembly
1 - LEVER 2 - MOUNTING BOLTS (6) 3 - WIRE HARNESS CLIP 4 - CALIBRATION SCREWS (NO ADJUSTMENT) 5 - APPS ASSEMBLY
(24) Remove the engine wire harness attaching bolt and wire harness push-in fastener from air inlet housing.
(25) Remove the air inlet housing and intake grid
heater from the intake manifold cover.
(26) Remove the two grid heater harness-to-cylin-
der head attaching bolts at front of cylinder head.
ENGINE 5.9L DIESEL
9 - 300
CYLINDER HEAD (Continued)DR
(e) Remove banjo fitting at bottom of fuel filter
housing.
(f) Disconnect fuel supply hose at lift pump.
(32) Disconnect fuel heater, water in fuel sensor,
and fuel lift pump connectors.
(33) Remove the fuel
filter assembly-to-cylinder head bolts and remove filter assembly from vehicle. (34) Remove wire harness P-clip from cylinder
head (located behind filter housing).
(35) Remove the cylinder head cover(Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(36) Disconnect rocker housing injector harness
connectors.
(37) Remove injector harness nuts from injectors. (38) Remove the rocker levers (Fig. 11), cross heads and push rods (Fig. 12). Mark each component so they can be installed in their original positions.
NOTE: The #5 cylinder exhaust and the #6 cylinder intake and exhaust push rods are removed by lift- ing them up and through the provided cowl panel access holes. Remove the rubber plugs to expose these relief holes.
Fig.11RockerArmandPedestalRemoval
1 - ROCKER ARM 2 - PEDESTAL
(39) Remove the fuel return line and banjo bolt at the rear of the cylinder head. Be careful not to drop the two (2) sealing washers.
(40) Remove the fuel injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - REMOVAL).
Fig.12PushRodRemoval
(41) Remove rocker housing bolts and rocker hous-
ing and gasket.
(42) Reinstall the engine lift bracket at the rear of
cylinder head. Torque to 77 N·m (57 ft. lbs.).
(43) Remove twenty six (26) cylinder head-to-block
(44) Attach an engine lift crane to engine lift brackets and lift cylinder head off engine and out of vehicle.
(45) Remove the head gasket and inspect for fail-
bolts.
ure.
CLEANING
CLEANING—CYLINDER HEAD
CAUTION: Do not wire brush head surface while fuel injectors are still installed. Fuel injector dam- age can result.
Remove fuel injector before cleaning (if not already
removed during cylinder head removal).
Clean the carbon from the injector nozzle seat with
a nylon or brass brush.
Scrape the gasket residue from all gasket surfaces. Wash the cylinder head in hot soapy water solution
(88°C or 140°F).
der head.
After rinsing, use compressed air to dry the cylin-
Polish the gasket surface with 400 grit paper. Use an orbital sander or sanding block to maintain a flat surface.
CLEANING—CROSSHEADS
Clean all crossheads in a suitable solvent. If neces- sary, use a wire brush or wheel to remove stubborn deposits. Rinse in hot water and blow dry with com- pressed air.
DR CYLINDER HEAD (Continued) CLEANING—PUSHRODS
Clean the pushrods in a suitable solvent. Rinse in hot water and blow dry with compressed air. If nec- essary, use a wire brush or wheel to remove stubborn deposits.
INSPECTION
INSPECTION - CYLINDER HEAD
Inspect the cylinder head for cracks in the combus- tion surface. Pressure test any cylinder head that is visibly cracked. A cylinder head that is cracked between the injector bore and valve seat can be pres- sure tested and reused if OK; however, if the crack extends into the valve seat insert bore, the cylinder head must be replaced.
Visually inspect the cylinder block and head com- bustion surfaces for localized dips or imperfections. Check the cylinder head and block combustion sur- faces for overall out-of-flatness. If either the visual or manual inspection exceeds the limits, then the head or block must be surfaced.
Check the top surface for damage caused by the
cylinder head gasket leaking between cylinders.
Inspect the block and head surface for nicks, ero-
sion, etc.
Check the head distortion. Maximum overall vari- ation end to end is 0.305 mm (0.012 inch) (Fig. 13), and maximum overall variation side to side 0.076
mm ( .003 in.).DO NOT proceed with the in-chassis overhaul if the cylinder head or block surface is damaged or not flat (within specifications).
Check block surface for distortion. Maximum vari- ation end-to-end is 0.076 mm ( .003 in.), side-to-side 0.051 mm (.002).
ENGINE 5.9L DIESEL
9 - 301
Visually inspect the cylinder head bolts for dam- aged threads, corroded/pitted surfaces, or a reduced diameter due to bolt stretching.
If the bolts are not damaged, their “free length” should be measured using the cap screw stretch gauge provided with the replacement head gasket. Place the head of the bolt against the base of the slot and align the bolt with the straight edge of gauge (Fig. 14). If the end of the bolt touches the foot of the gauge, the bolt must be discarded. The maximum bolt free length is 132.1 mm (5.200 in.).
Fig.14HeadBoltStretchGauge
INSPECTION—CROSSHEADS
Inspect the crossheads for cracks and/or excessive wear on rocker lever and valve tip mating surfaces (Fig. 15). Replace any crossheads that exhibit abnor- mal wear or cracks.
Fig.13CylinderHeadCombustionDeckFace
1 - STRAIGHT EDGE 2 - FEELER GAUGE
Fig.15InspectingCrossheadforCracks
ENGINE 5.9L DIESEL
9 - 302
CYLINDER HEAD (Continued) INSPECTION—PUSHRODSInspect the push rod ball and socket for signs of scoring. Check for cracks where the ball and the socket are pressed into the tube (Fig. 16).
Roll the push rod on a flat work surface with the socket end hanging off the edge (Fig. 17). Replace any push rod that appears to be bent.
DR
(b) Back off 360 degrees in sequence (c) Torque bolts to 105 N·m (77 ft. lbs.) (d) Re-check all bolts to 105 N·m (77 ft. lbs.) (e) Tighten all bolts an additional 1⁄4 turn (90°)
Fig.16InspectingPushRodforCracks
Fig.18CylinderHeadBoltTorqueSequence
(4) Install push rods into their original locations (Fig. 19). Verify that they are seated in the tap- pets.
Fig.17InspectingPushRodforFlatness
INSTALLATION
WARNING: THE OUTSIDE EDGE OF THE HEAD GASKET IS VERY SHARP. WHEN HANDLING THE NEW HEAD GASKET, USE CARE NOT TO INJURE YOURSELF.
(1) Install a new gasket with the part number side
up, and locate the gasket over the dowel sleeves.
(2) Using an engine lifting crane, lower the cylin-
der head onto the engine.
(3) Lightly lubricate head bolts with engine oil and install. Using the sequence shown in (Fig. 18), tighten bolts in the following steps:
(a) Torque bolts to 70 N·m (52 ft. lbs.)
Fig.19PushRodInstallation
(5) Lubricate valve stem tips and install the cross-
heads in their original locations.
(6) Lubricate the rocker arms and pedestals and install them in their original locations (Fig. 20). Install the bolts and torque them to 36 N·m (27 ft. lbs.).
(7) Verify that the valve lash settings are main- tained (Refer to 9 - ENGINE/CYLINDER HEAD/IN- TAKE/EXHAUST VALVES & SEATS - STANDARD PROCEDURE).
(8) Inspect rocker housing gasket for cuts and proper installation into groove. Replace if damaged.
DR CYLINDER HEAD (Continued)
ENGINE 5.9L DIESEL
9 - 303
(d) Install fuel line brace bolts-to-intake mani-
fold finger tight.
Nm ( 22 ft. lbs.).
(22 ft. lbs.)
(22 ft. lbs.).
(e) Hand tighten fuel pump to fuel rail line. (f) Torque fuel line nuts at cylinder head to 30
(g) Torque fuel line nuts at fuel rail to 30 Nm
(h) Torque fuel pump to fuel rail line to 30 Nm
(i) Torque fuel drain banjo bolt at pressure lim- iting valve and front of fuel filter housing to 24 Nm (18 ft. lbs.).
(j) Torque fuel line brace bolts to 24 N·m (18 ft.
lbs.).
(k) Torque rail bolts to 24 Nm (18 ft. lbs.). (l) Connect fuel pressure sensor.
(20) Install the engine lift bracket at the rear of
cylinder head. Torque to 77 N·m (57 ft. lbs.).
(21) Reposition number 6 fuel
line shield and
torque to 43 N·m (32 ft. lbs.).
(22) Install the fuel filter to injection pump low pressure line. Inspect and replace sealing washers if necessary. Torque banjo bolts to 24 N·m (18 ft. lbs.). (23) Connect fuel return line at back of cylinder
head hand tight.
(24) Connect fuel return line at filter housing hand
(25) Torque banjo connections at cylinder head and
fuel filter housing to 24 Nm (18 ft. lbs.)
(26) Install bracket
to rear of
filter housing.
Torque to 24 Nm (18 ft. lbs.).
(27) Using new gaskets,
install the intake grid heater and air inlet housing. Torque bolts to 24 N·m (18 ft. lbs.).
(28) Install wire harness P-clip and push on clip to
air inlet housing.
(29) Connect engine oil level indicator tube at fuel
filter housing and at air inlet housing.
(30) Connect the APPS connector. (31) Install the APPS assembly to the cylinder head bracket and torque bolts to 24 N·m (18 ft. lbs.).
(32) Install the throttle linkage cover. (33) Install the charge air cooler-to-air inlet hous- ing duct assembly. Torque all clamps to 11 N·m (100
in. lbs.).(34) Connect intake grid heater wires. (35) Secure engine harness to front of cylinder
head with bolt at four locations.
(36) Connect engine coolant temperature sensor
(37) Connect radiator upper hose to thermostat
(38) Rotate generator into position. Install upper
bolt and torque upper and lower bolts.
(39) Install wire harness push-on clip below
Fig.20RockerArmandPedestalRemoval
1 - ROCKER ARM 2 - PEDESTAL
(9) Install rocker housing and bolts. Tighten to 24
tight.
Nm (18 lb. ft.).
TEM/FUEL INSTALLATION).
(10) Install fuel injector(Refer to 14 - FUEL SYS-
INJECTION/FUEL
INJECTOR
(11) Install fuel injector tube and fuel injector tube
nut. Torqu to 50 N·m (37 ft. lbs.).
(12) Install injector harness nuts. Tighten to 1.5
Nm (13 lb. in.).
(13) Install cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
(14) Install wire harness P-clip to cylinder head
behind filter housing 24 N·m (18 ft. lbs.).
(15) Connect the IAT and MAP sensor connector. (16) Install the fuel filter canister assembly and
torque mounting bolts to 24 N·m (18 ft. lbs.).
(17) Connect fuel lift pump, WIF sensor, and fuel
(18) Remove the engine lift bracket at rear of cyl-
heater.
inder head.
CAUTION: Failure to follow procedure will result in fuel leaks and/or fuel system failure.
(19) Install the fuel rail and high pressure
fuel lines as follows:
(a) Hand tighten fuel rail bolts. (b) Hand tighten fuel drain line to pressure lim-
iting valve. Hand tighten at fuel filter housing.
(c) Hand tighten fuel rail-to-cylinder head lines.
connector.
housing.
bracket.
ENGINE 5.9L DIESEL
9 - 304
CYLINDER HEAD (Continued)(40) Install wire harness P-clip to top of bracket. (41) Install fan support and torque to 32 N·m (24
(42) Install cooling fan/drive and torque to 33 N·m
ft. lbs.).
(24 ft. lbs.).
(43) Install accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
(44) Install exhaust manifold/turbocharger assem- bly, using new gaskets. Start all bolts/spacers by hand. Torque bolts to 43 N·m (32 ft. lbs.).
(45) Install exhaust manifold heat shield. Torque
to 24 N·m (18 ft. lbs.).
(46) Install exhaust bolt retention straps across
cylinders 5 & 6.
8 N·m (71 in. lbs.).
(47) Connect turbocharger oil drain tube. Torque to
(48) Perform the turbocharger pre-lube procedure. Refer to Group 11, Exhaust System and Turbo- charger for the correct procedure.
(49) Connect
the turbocharger oil supply line.
Torque to 24 N·m (18 ft. lbs.).
(50) Install air cleaner housing and duct. (51) Connect air inlet temperature/pressure sensor. (52) Raise vehicle on hoist. (53) Install exhaust pipe to turbocharger elbow.
Torque bolts to 8 N·m (72 in. lbs.).
(54) Lower vehicle. (55) Fill engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(56) Start engine and check for leaks.
CYLINDER HEAD COVER(S)
REMOVAL
REMOVAL—CYLINDER HEAD COVER
(1) Disconnect both battery negative cables. (2) Remove oil fill cap. (3) Remove the breather cover. (4) Disconnect
the breather hose and breather
drain tube from the breather housing.
(5) Remove cylinder head cover bolts. (6) Remove the cylinder head cover.
REMOVAL—ROCKER HOUSING
(1) Remove cylinder head cover as outlined in this
(2) Disconnect rocker housing injector harness con-
section.
nectors.
(3) Remove injector harness nuts from injectors. (4) Remove rocker housing bolts. (5) Remove rocker housing and gasket.
DR
CLEANING
Using a suitable solvent, Clean and dry gasket mating surfaces on cylinder head and rocker housing. Wipe gasket dry and inspect for re-use.
INSPECTION
The cylinder head cover gasket, rocker hous- ing gasket, are reusable. However, should cracks, nicks, or tears be present in the rubber/silicone con- struction, should be replaced. Also replace gasket if it is no longer flexi- ble. Inspect o-rings on cylinder head cover bolts.
the defective
components
INSTALLATION
INSTALLATION—CYLINDER HEAD COVER
(1) Inspect cylinder head cover gasket for cuts and
proper installation in groove. Replace if damaged.
(2) Position cylinder cover on top of rocker hous-
ing.
(18 ft. lbs.).
(3) Install bolts. (4) Starting with the center bolt, torque to 24 N·m
(5) Install breather hose to breather. (6) Install breather drain hose to breather. (7) Install breather cover and wire harness clip.
Torque to 24 N·m (18 ft. lbs.).
INSTALLATION—ROCKER HOUSING
(1) Inspect rocker housing gasket for cuts, nicks, or tears. Replace if damaged or if gasket has come out of groove.
(2) Inspect rocker housing gasket for proper instal- lation in groove. Gasket bead must be centered in groove. A gasket bead that is tilted to the side will cause an oil leak.
(3) Install Tool XXXX guide pins (or equivalent) into the cylinder head at rocker housing bolt loca- tions #1 and #5.
(4) Install the rocker hoiusing over the guide pins. Carefully gyide the rocker housing evenly down onto the cylinder head.
(5) With guide pins in place,
install remaining
rocker housing bolts and tighten finger tight.
(6) Remove guide pins and install
remaining
rocker housing bolts finger tight.
(7) Install rocker housing and bolts. Torque bolts,
working from center out, to 24 Nm (18ft. lbs.).
(8) Install injector harness nuts to injector sole-
noid. Torque to 1.5 Nm (13 in. lbs.).
(9) Connect rocker housing injector harness con-
nections.
DR
ENGINE 5.9L DIESEL
9 - 305
INTAKE/EXHAUST VALVES & SEATS DESCRIPTION
The valves are made of heat resistant steel, and have chrome plated stems to prevent scuffing. The intake and exhaust valves are both similar in head diameter and overall length, but they have unique face angles which makes them non-interchangeable. The valves are distinguished by unique dimples on the exhaust valve head (Fig. 21).
The exhaust valve springs are made from high strength, chrome silicon steel. The exhaust valve springs are also exhaust brake compatible.
Fig.21ValveIdentification
1 - INTAKE VALVES 2 - EXHAUST VALVES
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVES, GUIDES AND SPRINGS
REMOVAL
(1) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(2) Support cylinder head on stands, or install head bolts upside down (through combustion surface side) to protect injector tips from damage from work bench.
(3) Install the valve spring compressor mounting
base as shown in (Fig. 22).
(4) Install the compressor top plate, washer, and nut. Using a suitable wrench, tighten the nut (clock- wise) to compress the valve springs (Fig. 23) and remove the locks.
(5) Rotate the compressor nut counter-clockwise to relieve tension on the springs. Remove the spring compressor.
(6) Remove the retainers, springs, valve seals (if necessary), and valves (Fig. 24). Arrange or number all components so they can be installed in their orig- inal locations.
(7) Repeat the procedure on all cylinders to be ser-
viced.
Fig.22SpringCompressorMountingBase—Partof
1 - COMPRESSOR MOUNTING BASE
Tool8319–A
Fig.23CompressingValveSpringswithTool
8319–A
1 - SPECIAL TOOL 8319
CLEANING
Clean the valve stems with crocus cloth or a Scotch-Brite™ pad. Remove carbon with a soft wire brush. Clean valves, springs, retainers, and valve retaining locks in a suitable solvent. Rinse in hot water and blow dry with compressed air.
ENGINE 5.9L DIESEL
9 - 306
INTAKE/EXHAUST VALVES & SEATS (Continued)DR
Measure the valve stem diameter in three places
as shown in (Fig. 26).
Fig.24ValveSpring,Seal,andRetainers
1 - VALVE RETAINING LOCKS 2 - VALVE 3 - SEAL 4 - SPRING 5 - RETAINER
INSPECTION
Visually inspect the valves for abnormal wear on the heads, stems, and tips. Replace any valve that is worn out or bent (Fig. 25).
Fig.25VisuallyInspectValvesforAbnormalWear
Fig.26MeasureValveStemDiameter
VALVE STEM DIAMETER 6.96 mm (0.2740 in.) MIN
7.010 mm (0.2760 in.) MAX
Measure the cylinder head valve guide bore (Fig. 27).
VALVE GUIDE BORE SPECIFICATIONS
VALVE GUIDE BORE SPECIFICATIONS
Valve guide bore diameter
Installed valve guide depth Intake
Exhaust
Min. Max.
7.027 mm (0.2767 in.) 7.077 mm (0.2786 in.)
Min. Max.
0.584 mm ( 0.023 in.) 1.092 mm ( 0.043 in.)
Min. Max.
0.965 mm ( 0.028 in.) 1.473 mm (0.058 in.)
Fig.27MeasureValveGuideBore
DR INTAKE/EXHAUST VALVES & SEATS (Continued)
Measure valve margin (rim thickness) (Fig. 28).
ENGINE 5.9L DIESEL
9 - 307
Fig.28MeasureValveMargin(RimThickness)
VALVE MARGIN (RIM THICKNESS)
0.79 mm (0.031 in.) MIN.
Measure the valve spring free length and maxi-
mum inclination (Fig. 29).
Fig.30TestingValveSpringwithToolC-647
1 - SPECIAL TOOL C-647
Fig.29MeasureValveSpringFreeLengthandMax.
Inclination
APPROXIMATE VALVE SPRING FREE LENGTH
47.75 mm (1.88 in.)
MAX INCLINATION
1.5 mm (.059 in.)
Test valve spring force with tool C-647 (Fig. 30). Specification 72.0 — 80.7 lbs. when compressed to 35.33 mm (1.39 in.).
INSTALLATION
(1) Install new valve seals. The yellow seals are for the intake valves and the green seals are for the exhaust valves.
(2) Install the valves in their original postion. The exhaust valves are identified by a dimple on the valve head (Fig. 31).
(3) Install the valve springs and retainer. (4) Install the valve spring compressor tool 8319–A
as shown in (Fig. 22) and (Fig. 23).
Fig.31ValveIdentification
1 - INTAKE VALVES 2 - EXHAUST VALVES
(5) Compress the valve springs and install the
valve retaining locks (Fig. 24).
(6) Remove the compressor and repeat the proce-
dure on the remaining cylinders.
(7) Install new o-ring and sealing washer on injec-
(8) Lubricate o-ring and injector bore. (9) Verify sealing washer (shim) was removed with
(10) Install
injector with fuel
injector connector
port facing intake manifold.
(11) Install hold-down bolt. Torque to 10 Nm (89
(12) Install fuel injector connector and connector
nut. Torque nut to 50 Nm (36.8 ft. lbs.).
(13) Install
the cylinder head (Refer
to 9 -
ENGINE/CYLINDER HEAD - INSTALLATION).
tor.
old injector.
in. lbs.).
ENGINE 5.9L DIESEL
9 - 308
INTAKE/EXHAUST VALVES & SEATS (Continued) STANDARD PROCEDURE - VALVE LASH ADJUSTMENT AND VERIFICATIONNOTE: To obtain accurate readings, valve lash mea- surements AND adjustments should only be per- formed when the engine coolant temperature is less than 60° C (140° F).
DR
The 24–valve overhead system is a “low-mainte- nance” design. Routine adjustments are no longer necessary, however, measurement should still take place when trouble-shooting performance problems, or upon completion of a repair that includes removal and installation of the valve train components or injectors.
(1) Disconnect battery negative cables. (2) Remove cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(3) Using the crankshaft barring tool #7471–B, rotate crankshaft to align damper TDC mark to 12:00 o’clock position.
(a) If both number one cylinder rocker levers are
loose, continue to next step.
(b) If both number one clylinder rocker levers
are not loose, rotate crankshaft 360 degrees. (4) With the engine in this position, valve lash can be measured at the following rocker arms: INTAKE 1–2–4 / EXHAUST 1–3–5. Measure the valve lash by inserting a feeler gauge between the rocker arm socket and crosshead (Fig. 32). Refer to VALVE LASH LIMIT CHART for the correct specifications. If the measurement falls within the limits, adjust- ment/resetting is not necessary. If measurement finds the lash outside of the limits, adjustment/re- setting is required.
VALVE LASH LIMIT CHART
INTAKE
EXHAUST
0.152 mm ( 0.006 in.)
0.381 mm (0.015 in.)
MIN.
MIN.
0.381 mm (0.015 in.)
0.762 mm (0.030 in.)
MAX.
MAX.
note: If measured valve lash falls within these specifications, no adjustment/reset is necessary. Engine operation within these ranges has no adverse affect on performance, emissions, fuel economy or level of engine noise.
Fig.32MeasuringValveLash-Typical
1 - INTAKE 2 - FEELER GAUGE 3 - EXHAUST
(5) If adjustment/resetting is required, loosen the lock nut on rocker arms and turn the adjusting screw until the desired lash is obtained: † INTAKE 0.254 mm (0.010 in.) † EXHAUST 0.508 mm (0.020 in.) Tighten the lock nut to 24 Nm (18 ft. lbs.) and re-check the valve lash.
(6) Using the crankshaft barring tool, rotate the to align the
crankshaft one revolution (360°) damper TDC mark to the 12 o’clock position.
(7) With the engine in this position, valve lash can be measured at the remaining rocker arms: INTAKE 3–5–6 / EXHAUST 2–4–6. Use the same method as above for determining whether adjustment is neces- sary, and adjust those that are found to be outside of the limits.
(8) Install the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION).
(9) Connect the battery negative cables.
REMOVAL - VALVE SPRINGS AND SEALS (1) Disconnect the battery negative cables. (2) Remove the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(3) Disconnect rocker housing injector harness con-
nector. Remove all injector harness solenoid nuts.
(4) Remove injector(s) for cylinder(s) to be serviced.
Refer to Group 14 for injector removal.
(5) Remove the rocker housing. (6) Remove the rocker arms and crossheads from the cylinder(s) to be serviced. Mark each component so they can be installed in their original position.
(7) Using the crankshaft barring tool #7471–B (Fig. 33), rotate the engine to position the damper
DR INTAKE/EXHAUST VALVES & SEATS (Continued)
ENGINE 5.9L DIESEL
9 - 309
35) to compress the valve springs and remove the collets.
(e) Rotate the compressor nut counter-clockwise to relieve tension on springs. Remove spring com- pressor.
(f) Remove and replace retainers, springs, and
seals as necessary.
(g) Do not rotate the engine until
the
springs and retainers are re-installed.
(h) Install seals, springs and retainers. Install spring compressor, compress valve springs and install the collets.
(i) Release the spring tension and remove the compressor. Verify that the collets are seated by tapping on the valve stem with a plastic hammer. (12) Using the crankshaft barring tool, rotate the engine until the next crankshaft damper paint mark aligns with the mark you placed on the cover. In this position, cylinders #2 and #5 can be serviced.
(13) Repeat the valve spring compressing proce- dure previously performed and service the retainers, springs, and seals as necessary.
(14) Using the crankshaft barring tool, rotate the engine until the next crankshaft damper paint mark aligns with the mark you placed on the cover. In this position, cylinders #3 and #4 can be serviced.
(15) Repeat the spring compressing procedure pre- viously performed and service the retainers, springs, and seals as necessary.
mark in the 12 o’clock position. At this engine posi- tion, cylinders #1 and #6 can be serviced.
(8) Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(9) With the damper TDC mark in the 12 o’clock position, add a paint mark anywhere on the gear housing cover next to the crankshaft damper. Place another mark on the vibration damper in alignment with the mark you just made on the cover.
(10) Divide the crankshaft damper
into three
equally sized segments as follows:
(a) Using a tape measure, measure the circum- ference of the crankshaft damper and divide the measurement by three (3).
(b) Measure that distance in a counter-clockwise direction from the first balancer mark and place another mark on the balancer.
(c) From the second damper mark, again mea- sure in a counter-clockwise direction and place a mark on the damper at the same distance you measured when placing the second damper mark. The damper should now be marked in three equally spaced locations and the damper TDC mark should be in the 12 o’clock position.
(d) Remove injectors, fuel lines, and high pres- sure connectors for every cylinder that requires repair.
Fig.33RotatingEnginewithBarringTool-Typical 1 - REAR FLANGE 2 - BARRING TOOL
(11) Compress the valve springs at cyls. #1 and #6
(a) Remove bolts and injector hold-down clamp. (b) Using miller special tool #9010, remove injec-
as follows:
tor.
Fig.34SpringCompressorMountingBase—Partof
1 - COMPRESSOR MOUNTING BASE
Tool8319–A
INSTALLATION
(1) Install rocker housing. (2) Install
fuel
injectors and high pressure fuel
(3) Lubricate the valve tips and install the cross-
heads in their original locations.
(c) Install the valve spring compressor mounting
lines.
base as shown in (Fig. 34).
(d) Install the top plate, washer, and nut. Using a suitable wrench tighten the nut (clock-wise) (Fig.
ENGINE 5.9L DIESEL
9 - 310
INTAKE/EXHAUST VALVES & SEATS (Continued)DR
der head. Mark the arms and pedestals so they can be installed in their original position.
CAUTION: When removing the rocker arms, the sockets (Fig. 37) may come loose and fall into the engine. Make sure they stay with the arm upon removal/installation.
(4) Lift the push rod(s) up and out of the engine (Fig. 38). Mark them so they can be installed in their original position.
NOTE: The #5 cyl. intake and exhaust and #6 cyl. intake and exhaust push rods must be raised through the provided cowl panel access holes.
(5) Lift the crosshead(s) off of the valve stems. Mark them so they can be installed in their original position.
Fig.35CompressingValveSpringswithTool
8319–A
1 - SPECIAL TOOL 8319
(4) Lubricate the crossheads and push rod sockets and install the rocker arms and pedestals in their original locations. Tighten bolts to 36 N·m (27 ft. lbs.) torque.
(5) Verify valve lash adjustment (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST VALVES & SEATS - STANDARD PROCEDURE). (6) Install cylinder head cover and reusable gasket (Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN- DER HEAD COVER(S) - INSTALLATION).
(7) Connect battery negative cables.
ROCKER ARM / ADJUSTER ASSY DESCRIPTION
The unique intake and exhaust rocker arms have their own rocker shafts and are lubricated by pas- sages intersecting the cylinder block main oil rifle. Crossheads are used, which allow each rocker arm to operate two valves.
The solid push rods are hardened at the rocker arm and tappet contact areas for superior strength and durability.
REMOVAL
(1) Disconnect the battery negative cables. (2) Remove cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
(3) Remove the rocker arm/pedestal fasteners (Fig. 36) and remove rocker arm and pedestal from cylin-
Fig.36RockerArmandPedestalRemoval
1 - ROCKER ARM 2 - PEDESTAL
CLEANING
Clean all components in a suitable solvent. If nec- essary, use a wire brush or wheel to remove stubborn deposits. Rinse in hot water and blow dry with com- pressed air. Inspect oil passages in rocker arms and pedestals. Apply compressed air to lubrication orifices to purge contaminants.
DR ROCKER ARM / ADJUSTER ASSY (Continued)
ENGINE 5.9L DIESEL
9 - 311
Fig.37RockerArmAssemblyIdentification
1 - NUT 2 - ADJUSTING SCREW 3 - ROCKER SHAFT 4 - RETAINER 5 - SOCKET
