DODGE RAM 1500 1998 2.G Workshop Manual

EXCESSIVE BLUE SMOKE
POSSIBLE CAUSE CORRECTION
Dirty air cleaner or restricted turbocharger intake duct. Check Filter MinderTat air filter housing. (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
ELEMENT - REMOVAL).
Air leak in boost system between turbocharger
compressor outlet and intake manifold.Service air charge system..
Obstruction in exhaust manifold. Remove exhaust manifold and inspect for blockage
(Refer to 9 - ENGINE/MANIFOLDS/EXHAUST
MANIFOLD - REMOVAL).
Restricted turbocharger drain tube. Remove turbocharger drain tube and remove
obstruction.
Crankcase ventilation system plugged. Inspect crankcase ventilation system for function
Valve seals are worn, brittle, or improperly installed. Replace valve stem oil seals (Refer to 9 - ENGINE/
CYLINDER HEAD/INTAKE/EXHAUST VALVES &
SEATS - REMOVAL).
Valve stems and/or guides are worn. Remove valves and inspect valves and guides. (Refer
to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
Broken or Improperly installed piston rings. Tear down engine and inspect piston rings.
Excessive piston ring end gap. Remove pistons and measure piston ring end gap
(Refer to 9 - ENGINE/ENGINE BLOCK/PISTON RINGS
- STANDARD PROCEDURE).
Excessive cylinder bore wear and taper. Remove pistons and measure cylinder bore wear and
taper (Refer to 9 - ENGINE/ENGINE BLOCK -
STANDARD PROCEDURE).
Cylinder damage. Remove pistons and inspect cylinder bore for cracks or
porosity. Repair with cylinder liner if necessary. (Refer
to 9 - ENGINE/ENGINE BLOCK - STANDARD
PROCEDURE).
Piston damage. 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).
Turbocharger failure. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - INSPECTION).
9 - 238 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

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. Use tool# 9011 to cap this fuel rail on the cyl-
inder being tested.
(6) Remove the exhaust rocker lever.
(7) Use Tool 9010 to remove the injector and cop-
per sealing washer.
(8) Install the exhaust rocker lever and torque to
36 N´m (27 ft. lbs.).
(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.
(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.
NOTE: The minimum cylinder pressure is 350 psi.
Cylinder pressure should be within 20% from cylin-
der to cylinder.
(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:²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any 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.
(9) Use Tool 9010 to remove the injector and cop-
per sealing washer.
(10) Install compression test Tool 9007 into the
injector bore.
(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, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN II
MopartEngine 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
DRENGINE 5.9L DIESEL 9 - 239
ENGINE 5.9L DIESEL (Continued)

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.
MOPARtATF RTV
MopartATF RTV is a specifically designed black
silicone rubber RTV that retains adhesion and seal-
ing properties to seal components exposed to auto-
matic transmission fluid, engine 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.
MOPARtGASKET MAKER
MopartGasket Maker is an anaerobic type gasket
material. The material cures in the absence of air
when squeezed between two metallic surfaces. It will
not cure if left in the uncovered tube. The anaerobic
material is for use between two machined surfaces.
Do not use on flexible metal flanges.
MOPARtGASKET SEALANT
MopartGasket 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. MopartGasket 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.
MopartGasket 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.
MopartEngine 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.MopartGasket 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.
Damaged or worn threads can be repaired. Essen-
tially, this repair consists of:
²Drilling out worn or damaged threads.
²Tapping the hole with a special Heli-Coil Tap, or
equivalent.
²Installing an insert into the tapped hole to bring
the hole back to its original thread size.
STANDARD PROCEDUREÐHYDROSTATIC
LOCK
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock
(regardless of what caused the problem), follow the
steps below.
(1) Disconnect the negative cable(s) from the bat-
tery.
(2) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(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.).
(6) Be sure all fluid has been removed from the
cylinders.
(7) Repair engine or components as necessary to
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-
TEM/FUEL INJECTION/FUEL INJECTOR -
INSTALLATION).
9 - 240 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

(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.
(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
oil.
(8) Reinstall drain plug. Tighten to 50N´m (37 ft.
lbs.) torque.
(9) Lower the vehicle.
(10) Remove fan/drive assembly. Refer to Section 7
± Fan/Drive Removal
(11) Remove radiator upper hose.
(12) Remove upper fan shroud mounting bolts.
(13) Disconnect the coolant recovery bottle hose
from the radiator fill neck and remove bottle.
(14) Using a 36mm wrench, remove viscous fan/
drive assembly. (Refer to 7 - COOLING/ENGINE/RA-
DIATOR FAN - REMOVAL).
(15) Remove cooling fan and shroud together.
(16) Disconnect heater core supply and return
hoses from the cylinder head fitting and coolant pipe.
(17) Raise vehicle on a hoist.
(18) Remove transmission and transfer case (if
equipped).
(19) Disconnect exhaust pipe from turbocharger
extension pipe.
(20) Disconnect engine harness to vehicle harness
connectors.
(21) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).(22) Remove flywheel/flexplate.
(23) Remove transmission adapter
(24) Disconnect A/C suction/discharge hose from
the rear of the A/C compressor.
(25) Lower vehicle.
(26) Disconnect lower radiator hose from radiator
outlet.
(27) Automatic transmission models:
(28) Disconnect transmission oil cooler lines from
in front of radiator using special tool #6931
(29) Remove radiator. (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(30) If A/C equipped, disconnect A/C condenser
refrigerant lines.
(31) Disconnect charge air cooler piping.
(32) Remove charge air cooler mounting bolts.
(33) Remove charge air cooler (and A/C condenser
if equipped) from vehicle.
(34) Remove damper and speed indicator ring from
front of engine.
(35) Disconnect engine block heater connector.
(36) Disconnect A/C compressor and pressure sen-
sor electrical connectors.
(37) Remove the passenger battery ground cable
from the engine block. Remove the driver side bat-
tery ground cable from the engine block.
(38) Remove power steering pump from engine by
removing 3 bolts.
(39) Remove accelerator linkage cover.
(40) Disconnect cables from on-engine APPS.
(41) Disconnect the ECM power connector.
(42) Disconnect the ECM ground wire from the
hydroform screw.
(43) Disconnect the fuel supply and return hoses.
(44) Remove the cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(45) Disconnect the 3 injector harness connectors
at the rocker housing. Disconnect the wire harnesses
from the injectors.
(46) Remove the rear engine lift bracket.
(47) Remove cylinder #4, #5, and #6 intake and
exhaust rocker arms, pedestals, and push tubes. Note
the original location for re-assembly.
(48) Loosen #6 fuel line shield bolts and rotate
shield out of the way.
(49) Remove cylinder #5 and #6 high pressure fuel
lines. Remove the fuel connector tube nut and fuel
connector tube. Remove cylinder #5 and #6 fuel injec-
tor.
(50) Remove rocker housing.
DRENGINE 5.9L DIESEL 9 - 241
ENGINE 5.9L DIESEL (Continued)

(51) Remove two cylinder head bolts according to
the diagram below and install Tool # 9009. Torque
bolts to 105N´m (77ft. lbs.) (Fig. 3).
(52) Loosen but do not remove engine mount
through bolts and nuts.
(53) Disconnect hood support struts and position
hood out of the way.
(54) Attach a chain with two hooks to the engine
lift brackets.
(55) While keeping engine level, lift straight up
out of the mounts.
(56) Rotate nose of engine upward and pull out of
chassis.
REMOVALÐCRANKCASE 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.
INSTALLATION
INSTALLATION - ENGINE
(1) Remove cylinder head bolts according to the
diagram below. Install special Tool 9009. Torque bolts
to 105N´m (77ft. lbs.)
(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 in 4 steps to:
²Step 1ÐTighten to 70 N´m (52 ft. lbs.) torque.
²Step 2ÐBack off 360É.
²Step 3ÐTighten to 105 N´m (77 ft. lbs.) torque.
²Step 4ÐRotate 90É.
(7) Install rocker housing. Torque to 24 N-m (18 ft-
lbs). Refer to (Refer to 9 - ENGINE/CYLINDER
HEAD/CYLINDER HEAD COVER(S) - INSTALLA-
TION).
Fig. 3 ENGINE LIFT BRACKET
1 - Head bolt
2 - Engine Lift Bracket
3 - Head Bolt
Fig. 4 Crankcase Breather Vapor Canister
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
9 - 242 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

(8) Replace injector o-ring and sealing washer on
injectors #5 and #6. Install injectors and torque using
the following steps:
²Step 1ÐInstall injector hold-down capscrews
and torque to 5 N´m (44 in. lbs.) torque.
²Step 2ÐLoosen injector hold-down capscrews.
²Step 3ÐInstall HPC connector tube and nut.
Torque nut to 15 N´m (11 ft. lbs.) torque.
²Step 4ÐTorque injector hold-down capscrews to
10 N´m (89 in. lbs.) torque.
²Step 5ÐTorque HPC connector tube nut to 50
N´m (37 ft. lbs.) torque.
(9) 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).
(10) Install rear engine lift bracket. Torque to 77
N-m (57 ft-lb).
(11) Install push tubes, rocker arms, and pedestals
for cylinders #4, #5, and #6. Torque the mounting
bolts to 36 N-m (27 ft-lbs).
(12) Reset valve lash on cylinders #4, #5, and #6.
Torque adjusting nuts to 24 N-m (18 ft-lbs).
(13) Install cylinder head cover. Torque to 24 N-m
(18 ft-lbs).(Refer to 9 - ENGINE/CYLINDER HEAD -
INSTALLATION).
(14) Connect breather tube and lube oil drain tube
to breather housing cover. Install breather housing.
Torque capscrews to 24 N-m (18 ft-lbs)
(15) Connect fuel supply and return hoses.
(16) Connect ECM ground to hydroform screw.
Connect ECM power connector.
(17) Install the APPS cable(s) to the APPS. Install
the throttle linkage cover.
(18) Install the power steering pump.
(19) Install the damper and speed indicator ring.
Torque to 40 N-m (30 ft-lb) plus 60 degrees.
(20) Connect the engine block heater connection.
(21) Connect the A/C compressor and pressure sen-
sor connectors
(22) 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).
(23) Connect the charge air cooler piping. Torque
all clamps to 8 N-m (72 in-lbs).
(24) Connect the a/c refrigerant lines to the a/c
condenser (if equipped).
(25) Install the radiator upper support panel.
(26) Install radiator.
(27) Connect the transmission quick-connect oil
cooler lines.(28) Raise vehicle.
(29) Connect a/c compressor suction/discharge hose
(if equipped).
(30) Install the radiator lower hose and clamps.
(31) Install the battery negative cables to the
engine block on the driver and passenger side.
(32) Install the transmission adapter with a new
camshaft rectangular ring seal. Torque to 77 N-m (57
ft-lb).
(33) Install the flywheel/flexplate. Torque to 137
N-m (101 ft-lb).
(34) Install the starter motor. Torque to 43 N-m
(32 ft-lb). (Refer to 8 - ELECTRICAL/STARTING/
STARTER MOTOR - INSTALLATION).
(35) Connect engine to vehicle harness connectors.
(36) Install transmission and transfer case (if
equipped).
(37) Connect the exhaust pipe to the turbocharger
elbow.
(38) Connect the transmission auxiliary oil cooler
lines (if equipped).
(39) Lower the vehicle.
(40) Connect the heater core supply and return
hoses.
(41) Install the cooling fan and upper fan shroud
at the same time. (Refer to 7 - COOLING/ENGINE/
RADIATOR FAN - INSTALLATION).
(42) Install the coolant recovery bottle.
(43) Install the windshield washer bottle.
(44) Install the upper radiator hose and clamps.
(45) Raise vehicle.
(46) Connect electronically controlled fan drive
wire harness. Install lower radiator fan shroud.
(47) Change oil filter and install new engine oil.
(48) Fill the cooling system with coolant. (Refer to
7 - COOLING - STANDARD PROCEDURE).
(49) Connect grid heater harness at grid heater
relays.
(50) Connect electrical connections to rear of alter-
nator.
(51) Start the engine and inspect for engine oil,
coolant, and fuel leaks.
INSTALLATIONÐCRANKCASE 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.
DRENGINE 5.9L DIESEL 9 - 243
ENGINE 5.9L DIESEL (Continued)

SPECIFICATIONS
SPECIFICATIONS - 5.9L DIESEL
GENERAL DESCRIPTION
DESCRIPTION SPECIFICATION
Engine Type In-Line 6 Cyl. Turbo
Diesel
Displacement 5.9 Liters
359 ( Cubic Inches)
Bore 102.0 mm (4.02 in.)
Stroke 120.0 mm (4.72 in.)
Compression Ratio 17.2:1
305/250/235 H.P Version
Cylinder Pressure
(Minimum)350 psi.
Horsepower High Output
48 RE A/T and NV 5600
M/T305 HP @ 2900 RPM
Horsepower Standard
Output 48 RE A/T and
NV 4500 M/T235 HP @ 2700 RPM
(CARB)
250 HP @ 2900 RPM
(49 State)
Torque Rating High
Output ( 48RE A/T and
NV 5600 M/T)555 LB-FT @ 1400 RPM
Torque Rating Standard
Output ( 48RE A/T and
NV 4500 M/T)460 LB-FT @ 1400 RPM
Lubrication System Pressure Feed-Full Flow
With Bypass Valve
Firing Order 1-5-3-6-2-4
Cylinder Block Cast Iron
Crankshaft Induction Hardened
Forged Steel
Cylinder Head Cast Iron With Valve Seat
Inserts
Combustion Chambers High Swirl Bowl
Camshaft Chilled Ductile Iron
Pistons Cast Aluminum
Connnecting Rods Cross Rolled Micro Alloy
PISTONS
DESCRIPTION SPECIFICATION
Metric Standard
Skirt Diameter 101.775 -
101.793 mm4.007 - 4.008 in.
Ring Groove
Clearance
Intermediate
(Min)0.045 mm .0018 in
(Max) 0.095 mm 0.0037 in.
Oil Control (Min) 0.040 mm .0016 in.
(Max) 0.085 mm .0033 in.
PISTON PINS
DESCRIPTION SPECIFICATION
Metric Standard
Pin Diameter
(Min)39.990 mm 1.5744 in.
(Max) 40.003 mm 1.5749 in.
Bore Diameter
(Min)40.006 mm 1.5750 in.
(Max) 40.012 1.5753 in.
PISTON RINGS
DESCRIPTION SPECIFICATION
Metric Standard
Ring Gap
Top Ring 0.26 - 0.36mm 0.010 - 0.014 in.
Intermediate 0.85 - 1.15 mm 0.033 - 0.045in.
Oil Control 0.25 - 0.55 mm 0.010 - 0.21 in.
9 - 244 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

CONNECTING RODS
DESCRIPTION SPECIFICATION
Metric Standard
Pin Bore
Diameter (Min.
w/ bushing
installed)40.019 mm 1.5764 in.
Pin Bore
Diameter (Max.
w/ bushing
installed)40.042 mm 1.5765 in.
Side Clearance
(Min)0.100 mm 0.004 in.
Side Clearance
(Max)0.330 mm 0.013 in.
CYLINDER HEAD
DESCRIPTION SPECIFICATION
Overall Flatness End To
End (max)0.305 mm (0.012 in.)
Overall Flatness Side To
Side (Max)0.076 mm (0.003 in.)
Intake Valve Seat Angle 30É
Exhaust Valve Seat Angle 45É
Valve Stem Diameter
(Min) 6.96 mm (0.2740 in.)
(Max) 7.01 mm (0.2760 in.)
Valve Rim Thickness
(Min.)0.79 mm (0.031 in.)
OIL PRESSURE
SPECIFICATION SPECIFICATION
At Idle 69 kPa (10 psi)
@ 2500 rpm 207 kPa (30 psi)
Regulating Valve
Opening Pressure517 kPa (75 psi)
Oil Filter Bypass
Pressure Setting344.75 kPa (50 psi)
TORQUE
TORQUE CHART 5.9L DIESEL ENGINE
DESCRIPTION N´mIn.
Lbs.Ft.
Lbs.
Connecting RodÐBolts
Step 1 30 Ð 22
Step 2 60 Ð 44
Step 3 Rotate 60 degrees
Crankshaft Main CapÐBolts
Step 1 50 37
Step 2 80 59
Step 3 Rotate 90É
Cylinder HeadÐBolts
Step 1 70 Ð 52
Step 2 Back off 360 degrees
Step 3 105 Ð 77
Step 4 Verify 105 Ð 77
Step 5 Rotate All Bolts 1/4
Turn
Cylinder Head Cover Bolts 24 Ð 18
Breather Cover Bolts 24 Ð 18
HPC Nut 50 37
Fuel Delivery LinesÐBanjo 24 Ð 18
Fuel Drain LineÐBanjo 24 Ð 18
Fuel lineÐrail to cylinder
head30 Ð 22
Fuel lineÐpump to fuel rail 36 Ð 27
Injector fuel line brace 24 Ð 18
Fuel rail holddown bolt 24 18
Oil PanÐBolts 28 Ð 21
Oil PanÐDrain Plug 50 Ð 37
Oil Pressure RegulatorÐPlug 80 Ð 59
Oil Pressure Switch 18 Ð 13
Oil PumpÐBolts
Step1 8 Ð 6
Step2 24 Ð 18
Oil Suction Tube (Flange)Ð
Bolts24 Ð 18
Oil Suction Tube (Brace)Ð
Bolt43 Ð 32
Rocker Arm/PedestalÐBolts 36 Ð 27
DRENGINE 5.9L DIESEL 9 - 245
ENGINE 5.9L DIESEL (Continued)

SPECIAL TOOLS
5.9L DIESEL ENGINE
Universal Driver Handle - C4171
Crankshaft Barring Tool - 7471 - B
Crankshaft Front Oil Seal Installer - 8281
Valve Spring Compressor - 8319A
Test Plug - 8442
Adapter - 8462
Engine Support Fixture - 8534
TAPPET INSTALLATION TOOL - 8502
STEEL BRACKET - 8534-A
9 - 246 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

Compression Test Adapter - 9007
Engine Lift Bracket - 9009
Fuel Injector Remover - 9010
FUEL BLOCKOFF PLUG - 9011
FUEL TEST FITTING - 9013
Fuel Injector Tube (Connector) Remover - 9015
TURBO TEST ADAPTER - 9022
DRENGINE 5.9L DIESEL 9 - 247
ENGINE 5.9L DIESEL (Continued)