DODGE TRUCK 1993 Service Repair Manual

TORQUE
SPECIFICATIONS

DESCRIPTION
TORQUE DESCRIPTION

TORQUE

Adjusting Strap Bolt... 23 N-m (200 in. lbs.)
Camshaft Bolt 68 N-m (50 ft. lbs.)
Camshaft Thrust Plate Bolts........................ 24 N-m (210 in. lbs.)
Chain Case Cover Bolts 41 N-m (30 ft. lbs.)
Connecting Rod Cap Bolts 61 N-m (45 ft. lbs.)
Crankshaft Main Bearing Cap Bolts 115 N-m (85 ft. lbs.)
Cylinder Head Bolts 1st Step 68 N-m (50 ft. lbs.)
2nd Step 143 N-m (105 ft. lbs.)
Cylinder Head Cover Bolts 11 N-m (95 in. lbs.)
Exhaust Manifold-to-Cylinder Head Bolts/Nuts 34 N-m (25 ft. lbs.)
Front Insulator Attaching Bolts (2WD).. 41 N-m (30 ft. lbs.)
Front Insulator Stud Nuts 102 N-m (75 ft. lbs.) Front Mount Adaptor-to-Block Bolts 41 N-m (30 ft. lbs.)
Front Mount Bracket-to- Crossmember Bolts (4WD) 41 N-m (30 ft. lbs.)

Generator
Mounting Bolt 41 N-m (30 ft. lbs.)
Intake Manifold Bolts Refer to Procedure in Service Manual.
Oil Pan Bolts 23 N-m (200 in. lbs.)
Oil Pan Drain Plug 34 N-m (25 ft. lbs.)
Oil Pump Attaching Bolts 41 N-m (30 ft. lbs.) Oil Pump Cover Bolts.. 11 N-m (95 in. lbs.) Rear Insulator-to-Bracket
Through-Bolt (2WD)................................. 68 N-m (50 ft. lbs.
Rear Insulator-to-Crossmember Support Bracket Nut (2WD) 41 N-m (30 ft. lbs.
Rear Insulator Mounting Plate-to- Rail Assembly Nuts (4WD) 41 N-m (30 ft. lbs.
Rear Support Bracket-to-Crossmember Flange Nuts 41 N-m (30
ft.
lbs.
Rear Support Plate-to-lnsulator Mounting Plate Bolts (4WD) 41 N-m (30
ft.
lbs.
Rear Support Plate-to-Transfer Case Bolts 41 N-m (30
ft.
lbs.
Rocker Arm Bolts 23 N-m (200 in. lbs.
Spark Plugs.... 41 N-m (30 ft. lbs.
Starter Mounting Bolts 68 N-m (50 ft. lbs.
Throttle Body Bolts (MPI)... 23 N-m (200 in. lbs. Torque Converter Drive Plate Bolts 31 N-m (270 in. lbs.
Transfer Case-to-Insulator Mounting Plate Nuts.... 204 N-m (150 ft. lbs.
Transmission Support Bracket Bolts (2WD).... 68 N-m (50 ft. lbs.
Transmission Support Spacer Bolts (4WD) 68 N-m (50
ft.
lbs.
Transmission Support Spacer-to- Insulator Mounting Plate Nuts (4WD) .... 204 N-m (150 ft. lbs.
Vibration Damper Retainer Bolt 183 N-m (135
ft.
lbs.
Water Pump-to-Chain Case Cover Bolt 41 N-m (30
ft.
Ibs.j

J9309-98

5.9L
ENGINE SERVICE PROCEDURES

INDEX

page
Camshaft
91

Crankshaft
98
Crankshaft Main Bearings
99

Crankshaft Rear
Oil
Seals
100

Cylinder
Block
101

Cylinder
Head Cover
81

Cylinder
Heads
82
Distributor
92

Engine Assembly
80

Engine
Front
Mounts
77

Engine Rear Mount
78

Front
Crankshaft
Oil
Seal Replacement
91
page
General
Information
77
Hydraulic
Tappets
87

Oil
Pan 93

Oil Pump
. 94

Piston
/
Connecting
Rod
Assembly
96

Rocker Arms
81

Specifications—5.9L
Engine
103

Timing
Chain Cover
89

Valve Stem Shield
/
Spring Replacement
86

Valve
Timing
. 88

Valves
/
Valve Springs
84

Vibration
Damper
88

GENERAL
INFORMATION
The 5.9 Liter (360 CID) eight-cylinder engine is a
V-Type lightweight, single cam, overhead valve en­
gine with hydraulic roller tappets (Fig. 1).
Engine Type .90° V-8 OHV
Bore and Stroke 101.6 x 90.9
mm
(4.00 x 3.58 in.)
Displacement 5.9L (360 cu. in.)
Compression Ratio 9.1:1
Torque 441 N-m (325 ft. lbs.) @ 3,200 rpm (Heavy Duty). 448 N-m (330 ft. lbs.)
@
2,800 rpm
Firing Order
1-8-4-3-6-5-7-2

Lubrication ...... Pressure Feed - Full Flow Filtration
Engine Oil Capacity .4.7L (5.0 Qts) w/filter
Cooling System . .
.
Liquid Cooled - Forced Circulation Cooling Capacity ..... . . 14.7L (15.5 Qts)
Ramcharger (4WD) 14.2L (15.0 Qts)
Cylinder Block Cast Iron Crankshaft
-
Nodular Iron
Cylinder Head • . Cast Iron Combustion Chambers Wedge-High Swirl Valve
Shrouding
Camshaft Nodular Cast Iron Pistons Cast Aluminum Alloy
Connecting Rods Forged Steel
J9309-99
Fig. 1
Engine
Description
This engine is designed for unleaded fuel.
Engine lubrication system consists of a rotor type
oil pump and a full flow oil filter.
The cylinders are numbered from front to rear; 1,

3,
5, 7 on the left bank and 2, 4, 6, 8 on the right
bank. The firing order is
1-8-4-3-6-5-7-2
(Fig. 2).
The engine serial number is stamped into a ma­
chined pad located on the left, front corner of the cyl­
inder block. When component part replacement is
necessary, use the engine type and serial number for
reference (Fig. 3).
o
FRONT OF
ENGINE CLOCKWISE ROTATION

1-8-4-3-6-5-7-2
J908D-49

Fig. 2 Firing Order

X
M 5.9L T
XXXX
XXXXXXXX

X
= Last Digit of Model Year
M = Plant - M Mound Road S Saltillo
T Trenton K Toluca
5.9L = Engine Displacement

T
= Usage -
T
Truck
XXXX
= Month/Day

XXXXXXXX
= Serial Code - Last 8 Digits of
VIN
No.
J9209-74

Fig.
3
Engine
identification
Number

ENGINE
FRONT MOUNTS
REMOVAL (1) Raise hood and position fan to assure clearance
for radiator top tank and hose.

9
- 78 5.9L ENGINE
•
CAUTION:
DO NOT
lift
the engine by the
intake

manifold.

(2)
Install an engine lifting fixture.
(3) Raise vehicle on hoist.
(4) Remove nuts from brackets and insulators (Fig,

4).
(5) Raise engine with lifting fixture only far
enough to remove insulators.

SCREW
<£>
SCREW
<B>

FRONT
#C3p
LOCATING
PIN
- -•- —
SIDE
ONLY
INSULATORS
^
4-WHEEL DRIVE

FRAME
SHOWN

INSULATOR

BRACKET

(FRONT
ENG
SUPPORT)

USE
FRONT
HOLES

FOR
INSULATOR
MTG.

2-WHEEL DRIVE
TIGHTENING TORQUE
75
FT.
LBS.
(102 N-m)
65
FT.
LBS.
(38
Hw)

<£) 30
FT.
LBS.

(41
N-m)

RIGHT
SIDE
4-WHEEL
DRIVE
LEFT
SIDE

2-WHEEL
DRIVE
RR09B145

Fig.
4 Engine Front
Mounts
(6) If necessary, remove the bracket from the block
(Fig. 4).

(7)
If necessary, remove the front engine support
bracket (Fig. 4).

INSTALLATION
(1) If removed, install the front engine support
bracket. Tighten the bolts to 41 N-m (30 ft. lbs.)
torque.
(2) If removed, position the bracket to the block.
Install the screws and tighten screw A to 102 Nrn (75 ft. lbs.) torque. Tighten screw B to 88 N-m (65 ft.
lbs.) torque.
(3) With engine raised slightly, install insulators.
(4) Lower engine with lifting fixture while guiding
insulator studs into attaching holes in crossmember and brackets (Fig. 4). (5) Tighten attaching insulator nuts to 102 N-m
(75 ft. lbs.) torque. (6) Lower the vehicle.

(7)
Remove lifting fixture.
engine rear
MOUNT

REMCYAL-2WD (1) Raise vehicle on a hoist.
(2) Position a transmission jack under the trans­
mission and raise rear of transmission and engine SLIGHTLY.
(3) Remove rear mount through-bolt from frame
crossmember (sport utility) or from the transmission support bracket (Fig. 5).
(4) Remove the flange nuts from the crossmember
support bracket (Fig. 5).
(5) Raise rear of transmission enough to provide
insulator to crossmember clearance. Remove the in­
sulator flange nuts and remove the insulator (Fig. 5).
(6) If necessary, remove the attaching bolts hold­
ing the transmission support bracket to the transmis­ sion (Fig. 5).
INSTALLATION-2WD (1) If removed, position the transmission support
bracket to the transmission (Fig. 5). Install the at­
taching bolts and tighten to 68 N-m (50 ft. lbs.) torque. (2) Position insulator in transmission support
bracket. Install through-bolt.
(3) Be sure insulator is secured in a LEVEL posi­
tion relative to transmission rear support bracket. Tighten the through-bolt nut to 68 N-m (50 ft. lbs.) torque.
(4) Position the crossmember support bracket onto
the insulator (Fig. 5). Install the flange nut(s) and
tighten to 41 N-m (30 ft. lbs.) torque.

(5)
Using the transmission jack, lower the insula­
tor and crossmember support bracket onto the cross-
member (Fig. 5).
(6) Tighten the crossmember flange nuts to 41 N-
m (30 ft. lbs.) torque. (7) Remove the transmission jack.
(8) Lower the vehicle.

REMOVAL-4WD
(1) Raise the vehicle on a hoist.
(2) Remove the skid plate (if equipped) from the
rear crossmember and transmission crossmember (Fig. 6). (3) Position transmission jack under transmission
and raise rear of transmission and engine
SLIGHTLY. (4) AUTOMATIC TRANSMISSION-Remove
the nuts and bolts holding the transmission support spacer to the insulator mounting plate (Fig. 7). Re­
move the bolts and nuts holding the engine rear sup­
port plate to the insulator mounting plate (Fig. 7).

TRANSMISSION

SUPPORT BRACKET

TRANSMISSION
TRANSMISSION
SUPPORT BRACKET

INSULATOR

CROSSMEMBER

(SPORT
UTILITY)
J9109-240

j
TRANSFER
CASE
f||

SKID
PLATE
llllpifci^—^

ATTACHING
BOLTS
ptllllSKiP
PLATE
f
FIG,
5
REAR
ENGINE

iSKID
PLATE

I
ATTACHING
BOLTSlt

PU873
FIG.
6
SKID
PLATE
(5)
MANUAL TRANSMISSION—Remove
the

nuts
and
bolts holding
the
insulator mounting plate
to
the
transfer case (Fig.
8).

(6) Remove insulator mounting bolts, spacers,
washers
and
upper/lower insulators (Figs.
7 and 8).
(7) Remove
the
insulator mounting plate (Figs.
7

and
8).
(8)
If
necessary, remove
the
transmission support
spacer (automatic transmission) from
the
extension
assembly (Fig.
7).

(9)
If
necessary, remove
the
engine rear support
bracket (automatic transmission) from
the
transfer case (Fig.
7).
Supporis-2WD

SNSTALLA
TION-4
WD
(1)
If
removed, position
the
engine rear support
bracket (automatic transmission)
to the
transfer case (Fig.
7).
Install
the
bolts
and
tighten
to 41 N«m (30

ft.
lbs.)
torque.
(2)
If
removed, position
the
transmission support
spacer (automatic transmission)
to the
extension
as­

sembly
(Fig. 1).
Install
the
bolts
and
tighten
to 68

N*m
(50 ft.
lbs.) torque.
(3) Install insulator mounting plate, mounting

bolts,
spacers, washers
and
upper/lower insulators
to

the rail assembly (Figs.
7 and
8). Tighten
the
mount­ ing bolt nuts
to 204
N*m
(150 ft. lbs.)
torque.

(4)
AUTOMATIC TRANSMISSION—Align
the

engine rear support plate
and the
transmission sup­
port spacer
to the
insulator mounting plate (Fig.
7).
Lower
the
engine
and
transmission onto
the
insula­
tor mounting plate
and
install
the
bolts. Tighten
the

transmission support spacer nuts
to 204
N*m (150
ft.
lbs.) torque. Tighten
the
engine rear support plate
to

41
Nnn (30 ft. lbs.)
torque. (5) MANUAL TRANSMISSION—Align
the

transfer case
to the
insulator mounting plate
and
lower
the
engine
and
transmission. Install
the
bolts and tighten
the
nuts (Fig.
8 - nut A) to 204
N-m (150
ft. lbs.) torque. Install
the
bolts
and
tighten
the
nuts (Fig.
8 - nut B) to 41 N-m (30 ft. lbs.)
torque (6) Install
the
skid plate.

9
- 80 5.9L
ENGINE

•

TRANSFER
CASE
TRANSFER

CASE
ENGINE REAR
SUPPORT
PLATE
INSULATOR

MOUNTING
PLATE

LOWER

INSULATOR

\7&#34;
RAIL
1
J9109-244

Fig.
7 Rear
Engine
Support—4WD
with
Automatic
Transmission
(7) Lower the vehicle.

ENGINE
ASSEMBLY

REMOVAL
(1) Scribe hood hinge outlines on hood. Remove the
hood. (2) Remove the battery.
(3) Drain cooling system (refer to Group 7, Cooling
System for the proper procedure). (4) Remove the air cleaner.
(5) Disconnect the radiator and heater hoses. Re­
move radiator (refer to Group 7, Cooling System). (6) Set fan shroud aside.
(7) Remove the vacuum lines.
(8) Remove the distributor cap and wiring.
(9) Disconnect the accelerator linkage.
(10) Remove MPI throttle body.
(11) Disconnect the fuel lines.
(12) Disconnect the starter wires.
(13) Disconnect the oil pressure wire.
(14) Discharge the air conditioning system, if
equipped (refer to Group 24, Heating and Air Condi­
tioning for service procedures).
(15) Disconnect the air conditioning hoses.
(16) Disconnect the power steering hoses, if
equipped.
INSULATOR

MOUNTING
PLATE
SPACER

UPPER

INSULATOR

NUT®

LOWER

INSULATOR
J9109-245

Fig.
8 Rear
Engine
Support—4WD
with
Manual

Transmission
(17) Remove starter motor (refer to Group 8B, Bat­
tery/Starter/Generator Service).
(18) Remove the generator (refer to Group 8B, Bat­
tery/Starter/Generator Service).
(19) Raise and support the vehicle on a hoist.
(20) Disconnect exhaust pipe at manifold.
(21) AUTOMATIC TRANSMISSION: (a) Support transmission. This will assure that
the torque converter will remain in proper position in the transmission housing. (b) Remove bell housing bolts and inspection
plate. (c) Attach a C-clamp on front bottom of trans­
mission torque converter housing to prevent torque converter from falling out. (d) Remove torque converter drive plate bolts
from torque converter drive plate. Mark converter and drive plate to aid in assembly.
(22) MANUAL TRANSMISSION; (a) Support transmission.
(b) Disconnect clutch release mechanism and re­
move transmission to clutch housing bolts.
CAUTION:

manifold.
DO
NOT
lift
the engine by the intake
(23) Install an engine lifting fixture.
(24) Remove engine front mount bolts.

•

5.9L ENGINE
9-81 (25) Lower the vehicle.
(26) On automatic transmission vehicles, discon­
nect the engine from the torque converter drive
plate. On manual transmission vehicles, move engine forward until drive pinion shaft clears the clutch

disc.
Remove engine from engine compartment.
(27) Install engine assembly on engine repair
stand.
INSTALLATION (1) Remove engine from the repair stand and posi­
tion in the engine compartment.
(2) Install an engine support fixture.
(3) Raise and support the vehicle on a hoist.
(4)
AUTOMATIC TRANSMISSION: (a) Position the torque converter and drive plate.
Install torque converter drive plate bolts. Tighten
the bolts to 31 Nnn (270 in. lbs.) torque.
(b) Install the engine front mounts.
(c) Install bell housing bolts. Tighten the bolts to
41 Nnn (30 ft. lbs.) torque.
(d) Remove C-clamp.
(e) Install the inspection plate.

(5)
MANUAL TRANSMISSION: (a) Position the drive pinion shaft to the clutch

disc.
(b) Connect the clutch release mechanism and
install the transmission to clutch bolts. Tighten the
bolts to 68 Nnn (50 ft. lbs.) torque.
(c) Install the engine front mounts.
(6) Remove transmission support.
(7) Install exhaust pipe to manifold. (8) Lower the vehicle.
(9) Remove engine lifting fixture.
(10) Install the generator (refer to Group 8B, Bat­
tery/Starter/Generator Service). (11) Install the starter motor (refer to Group 8B,
Battery/Starter/Generator Service).
(12) Connect power steering hoses, if so equipped.
(13) Connect air conditioning hoses.
(14) Evacuate and charge the air conditioning sys­
tem, if equipped (refer to Group 24, Heater and Air Conditioning for service procedures).
(15) Using a new gasket, install MPI throttle body.
Tighten the throttle body bolts to 23 Nnn (200 in. lbs.) torque.
(16) Connect the accelerator linkage. (17) Connect the starter wires.
(18) Connect the oil pressure wire.
(19) Install the distributor cap and wiring.
(20) Connect the vacuum lines.
(21) Connect the fuel lines.
(22) Install the radiator (refer to Group 7, Cooling
System). Connect the radiator hoses and heater

hoses.

(23) Install fan shroud in position.
(24) Fill cooling system (refer to Group 7, Cooling
System for the proper procedure). (25) Install the air cleaner.
(26) Install the battery.
(27) Warm engine and adjust.
(28) Install hood and line up with the scribe
marks. (29) Road test vehicle.

CYLINDER HEAD COVER
A steel backed silicon gasket is used with the cyl­
inder head cover (Fig. 1). This gasket can be used
again.

CYLINDER HEAD

J9209-105

Fig.
1 Cylinder Head
Cover
Gasket

REMOVAL (1) Disconnect the negative cable from the battery.
(2) Disconnect closed ventilation system and evap­
oration control system from cylinder head cover.
(3) Remove cylinder head cover and gasket. The
gasket may be used again.

CLEANING
Clean cylinder head cover gasket surface.
Clean head rail, if necessary.
INSPECTION Inspect cover for distortion and straighten, if nec­
essary.
Check the gasket for use in head cover installation.
If damaged, use a new gasket.
INSTALLATION (1) The cylinder head cover gasket can be used
again. Install the gasket onto the head rail.
(2) Position the cylinder head cover onto the gas­
ket. Tighten the bolts to 11 Nnn (95 in. lbs.) torque. (3) Install closed crankcase ventilation system and
evaporation control system.
(4) Connect the negative cable to the battery.

ROCKER
ARMS

REMOVAL (1) Disconnect spark plug wires by pulling on the
boot straight out in line with plug.
(2) Remove cylinder head cover and gasket.

9
- 82 5.9L
ENGINE

• (3) Remove the rocker arm bolts and pivots (Fig.

2).
Place them on a bench in the same order as re­
moved. (4) Remove the push rods and place them on a
bench in the same order as removed.
ROCKER
CYLINDER

J9209-65

Fig.
2
Rocker Arms INSTALLATION

(1) Rotate the crankshaft until the &#34;V8&#34; mark
lines up with the TDC mark on the timing chain
case cover. This mark is located 147° ATDC from the
No.l firing position.

CAUTION:
DO NOT
rotate
or crank the engine dur­
ing
or
immediately
after
rocker
arm installation. Al­
low the hydraulic roller tappets adequate
time
to
bleed
down
(about 5 minutes).
(2) Install the push rods in the same order as re­
moved.
(3) Install rocker arm and pivot assemblies in the
same order as removed. Tighten the rocker arm bolts
to 28 N*m (21 ft. lbs.) torque. (4) Install cylinder head cover.
(5) Connect spark plug wires.
CYLINDER HEADS The alloy cast iron cylinder heads (Fig. 3) are held
in place by 10 bolts. The spark plugs are located in
the peak of the wedge between the valves. The 5.9L cylinder head is identified by the foundry
mark CF.

REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Drain cooling system (refer to Group 7, Cooling
System for the proper procedures).
(3) Remove the heat shields (Fig. 4).
(4) Remove the intake manifold-to-generator
bracket support rod. Remove the generator.
(5) Remove closed crankcase ventilation system. (6) Disconnect the evaporation control system.
(7) Remove the air cleaner.
(8) Disconnect the fuel lines.
(9) Disconnect accelerator linkage and if so
equipped, the speed control and transmission kick- down cables.
EXHAUST SPARK EXHAUST SPARK EXHAUST
VALVE PLUGS VALVES PLUGS VALVE
INTAKE INTAKE

VALVES
VALVES
J9309-37

Fig.
3 Cylinder Head
Assembly
Fig.
4
Exhaust
Manifold Heat
Shields
(10) Remove the return spring.
(11) Remove distributor cap and wires.
(12) Disconnect the coil wires.
(13) Disconnect heat indicator sending unit wire.
(14) Disconnect heater hoses and bypass hose.
(15) Remove cylinder head covers and gaskets.
(16) Remove intake manifold and throttle body as
an assembly. Discard the flange side gaskets and the
front and rear cross-over gaskets.
(17) Remove exhaust manifolds.
(18) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations. (19) Remove the head bolts from each cylinder
head and remove cylinder heads. Discard the cylin­ der head gasket.
(20) Remove spark plugs.

CLEANING
Clean all surfaces of cylinder block and cylinder

heads.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.

•
IJL ENGINE 9 - 83
INSPECTION

Inspect all surfaces with a straightedge if there is
any reason to suspect leakage. If out-of-flatness ex­
ceeds 0.00075 mm/mm (0.00075 inch/inch) times the span length in inches in any direction, either replace
head or lightly machine the head surface.
FOR EXAMPLE: A 305 mm (12 inch) span is
0.102 mm (0.004 inch) out-of-flat. The allowable out-
of-flat is 305 x 0.00075 (12 x 0.00075) equals 0.23
mm (0.009 inch). This amount of out-of-flat is accept­
able.

The cylinder head surface finish should be 1.78-
4.57 microns (70-180 microinches). Inspect push rods. Replace worn or bent rods.

INSTALLATION
(1) Apply Perfect Sealant No.5, or equivalent, to
both sides of the gasket (Fig. 5).

Fig.
5 Sealant Location on Cylinder Head
Gasket

(2) Position the new cylinder head gaskets onto the
cylinder block.
(3) Position the cylinder heads onto head gaskets
and cylinder block. (4) Starting at top center, tighten all cylinder head

bolts,
in sequence, to 68 N-m (50 ft. lbs.) torque (Fig.
6).
Repeat procedure, tighten all cylinder head bolts
to 143 N-m (105 ft. lbs.) torque. Repeat procedure to confirm that all bolts are at 143 N-m (105 ft. lbs.)
torque.

CAUTION:
When
tightening the rocker arm
bolts,
make
sure
the
piston
in
that
cylinder is NOT at

TDC.
Contact
between the
valves
and
piston
could
occur.

(5) Install push rods and rocker arm assemblies in
their original position. Tighten the bolts to 28 N-m (21 ft. lbs.) torque. (6) Place the 4 plastic locator dowels into the holes
in the block Fig. 7).
Fig.
6 Cylinder Head
Bolt
Tightening
Sequence

(7) Apply Mopar Silicone Rubber Adhesive Seal­
ant, or equivalent, to the four corner joints. An ex­
cessive 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 slightly highe^ than
the cross-over gaskets, approx. 5 mm (0.2 in).
(8) Install the front and rear cross-over gaskets
onto the dowels (Fig. 7).

FRONT
CROSS-OVER GASKET
REAR CROSS-OVER GASKET
J9209-99

Fig.
7
Cross-Over
Gaskets
and Locator
Dowels

(9) Install the flange gaskets. Be sure 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. 8). The words MANIFOLD SIDE should be
visible on the center of each flange gasket.
(10) Carefully lower intake manifold into position
on the cylinder block and cylinder heads. Use the

FLANGE GASKET

Fig. 8 Intake Manifold Flange Gasket Alignment alignment dowels in the cross-over gaskets to posi­
tion the intake manifold. After intake manifold is in
place, inspect to make sure seals are in place.
(11) The following torque sequence duplicates the
expected results of the automated assembly system (Fig. 9).

J9209-60

Fig. 9 Intake Manifold Bolt Tightening Sequence
• Step
1—Tighten
bolts 1 through 4, in sequence, to 8 N-m (72 in. lbs.) torque. Tighten in alternating
steps 1.4 N-m (12 in. lbs.) torque at a time.
• Step 2—Tighten bolts 5 through 12, in sequence,
to 8 N-m (72 in. lbs.) torque. • Step 3—-Check that all bolts are tighten to 8 N-m
(72 in. lbs.) torque.
• Step 4—Tighten all bolts, in sequence, to 16 N-m (12 ft. lbs.) torque.
• Step 5—Check that all bolts are tighten to 16 N-m (12 ft. lbs.) torque.
(12) Install exhaust manifolds. Tighten the bolts
and nuts to 34 N-m (25 ft. lbs.) torque.
(13) Adjust spark plugs to specifications (refer to
Group 8D, Ignition System). Install the plugs and
tighten to 41 N-m (30 ft. lbs.) torque. (14) Install coil wires. (15) Connect heat indicator sending unit wire.
(16) Connect the heater hoses and bypass hose.
(17) Install distributor cap and wires.
(18) Hook up the return spring.
(19) Connect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(20) Install the fuel lines.
(21) Install the generator and drive belt. Tighten
generator mounting bolt to 41 N-m (30 ft. lbs.)
torque. Tighten the adjusting strap bolt to 23 N-m (200 In. lbs.) torque. Refer to Group 7, Cooling Sys­
tem for adjusting the belt tension.
(22) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts.
(23) Place the cylinder head cover gaskets in posi­
tion and install cylinder head covers. Tighten the
bolts to 11 N-m (95 in. lbs.) torque.
(24) Install closed crankcase ventilation system.
(25) Connect the evaporation control system.
(26) Install the air cleaner.
(27) Install the heat shields. Tighten the bolts to
41 N-m (30 ft. lbs.) torque. (28) Fill cooling system (refer to Group 7, Cooling
System for proper procedure).
(29) Connect the negative cable to the battery.

¥AL¥ES
/
WALWE SPRIliS
The valves are arranged in-line and inclined 18°.
The rocker pivot support and the valve guides are cast integral with the heads. This procedure requires the removal of the cylinder
head.
REMOVAL (1) Remove the cylinder head.
(2) Compress valve springs using Valve Spring
Compressor Tool MD-998772A.
(3) Remove valve retaining locks, valve spring re­
tainers, valve stem seals and valve springs.
(4) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
valve guides. Identify valves to ensure Installation in original location,

VALVE
CLEANING Clean valves thoroughly. Discard burned, warped
and cracked valves.
Remove carbon and varnish deposits from Inside of
valve guides with a reliable guide cleaner.

VALVE
INSPECTION Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 Inch), replace the valve.
Measure valve stem guide clearance as follows: (a) Install Valve Guide Sleeve Tool C-3973 over
valve stem and install valve (Fig. 10). The special

•
5.9L
ENGINE
9 - 85 sleeve places the valve at the correct height for
checking with a dial indicator.

Fig.
11
Measuring
Valve
Guide
Wear
(c) Move valve to and from the indicator. The to­
tal dial indicator reading should not exceed 0.432
mm (0.017 inch). Ream the guides for valves with
oversize stems if dial indicator reading is excessive
or if the stems are scuffed or scored. Service valves with oversize stems are available
(Fig. 12).

Reamer O/S Valve Guide Size
0.076
mm
8.026
-
8.052
mm

(0.003
in.)
(0.316-0.317
in.)

0.381
mm
8.331
-
8.357
mm

(0.015
in.)
(0.328-0.329
in.)

J9309-30
Fig.
12
Reamer
Sizes
Slowly turn reamer by hand and clean guide thor­
oughly before installing new valve. Ream the valve
guides from standard to 0.381 mm (0.015 inch).
Use a 2 step procedure so the valve guides are
reamed true in relation to the valve seat:
• Step
1-Ream
to 0.0763 mm (0.003 inch).
• Step 2-Ream to 0.381 mm (0.015 inch).
REFACING VALVES / VALVE SEATS The intake and exhaust valves have a 43-1/4° to
43-3/4° face angle and a 44-1/4° to 44-3/4° seat angle (Fig. 13).

CONTACT

A
-
SEAT
WIDTH
-
INTAKE
1.016-1.524
mm
(0.040
-
0.060
in.)
EXHAUST
1.524 -
2.032
mm
(0.060
-
0.080
in.)

B
-
FACE ANGLE (INTAKE
&
EXHAUST)
4374°-433/4°

C
-
SEAT ANGLE (INTAKE
&
EXHAUST)
447/ - 443A°
D
-
CONTACT SURFACE

J9309-95

Fig.
13
Valve
Face and
Seat
Angles

VALVES
Inspect the remaining margin after the valves are
refaced (Fig. 14). Valves with less than 1.190 mm (0.047 inch) margin should be discarded.

VALVE
SEATS
CAUTION:
DO NOT
un-shroud valves during valve
seat refacing
(Fig. 15).
(1) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat­ ing stones. A true and complete surface must be ob­
tained.
(2) Measure the concentricity of valve seat using a
dial indicator. Total runout should not exceed 0.051
mm (0.002 inch) total indicator reading.
(3)
Inspect the valve seat with Prussian blue to de­
termine where the valve contacts the seat. To do

this,
coat valve seat LIGHTLY with Prussian blue
then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of