DODGE TRUCK 1993 Service Repair Manual

9
- 96 5.9L
ENGINE

•

Fig.
11 Proper installation of Retainer Cap
ASSEMBLE

(1)
Install pump rotors and shaft, using new parts
as required.

(2)
Position the oil pump cover onto the pump
body. Tighten cover bolts to 11 N-m (95 in. lbs.) torque.

(3)
Install the relief valve and spring. Insert the
cotter pin.
(4)
Tap on a new retainer cap.

(5)
Prime oil pump before installation by filling ro­
tor cavity with engine oil.

INSTALLATION
(1) Install oil pump. During installation slowly ro­
tate pump body to ensure driveshaft-to-pump rotor shaft engagement.

(2)
Hold the oil pump base flush against mating
surface on No.4 main bearing cap. Finger tighten
pump attaching bolts. Tighten attaching bolts to 41 N-m (30 ft. lbs.) torque.
(3)
Install the oil pan.

PISTON
/
CONNECTING ROD ASSEMBLY
The pistons are elliptically turned so that the di­
ameter at the pin boss Is less than its diameter
across the thrust face. This allows for expansion un­
der normal operating conditions. Under operating temperatures, expansion forces the pin bosses away
from each other, causing the piston to assume a more
nearly round shape.
All pistons are machined to the same weight, re­
gardless of size, to maintain piston balance.
The piston pin rotates in the piston only and is re­
tained by the press interference fit of the piston pin in the connecting rod.

REMOVAL
(1) Remove the engine from the vehicle.
(2) Remove the cylinder head.
(3) Remove the oil pan.

(4)
Remove top ridge of cylinder bores with are li­
able ridge reamer before removing pistons from cyl­
inder block. Be sure to keep tops of pistons covered
during this operation.

(5)
Be sure the connecting rod and connecting rod
cap are identified with the cylinder number. Remove
connecting rod cap. Install connecting rod bolt guide
set on connecting rod bolts. (6) Pistons and connecting rods must be removed
from top of cylinder block. When removing piston and connecting rod assemblies from the engine, ro­
tate crankshaft so that the connecting rod is centered in cylinder bore and at BDC. Be careful not to nick crankshaft journals. (7) After removal, install bearing cap on the mat­
ing rod.
INSPECTION Check the crankshaft connecting rod journal for ex­
cessive wear, taper and scoring. Check the cylinder block bore for out-of-round,
taper, scoring and scuffing. Check the pistons for taper and elliptical shape be­
fore they are fitted into the cylinder bore (Fig. 12).
FITTING PISTONS Piston and cylinder wall must be clean and dry.
Specified clearance between the piston and the cylin­
der wall is 0.013-0.038 mm
(0.0005-0.0015
inch).
Piston diameter should be measured at the top of
skirt, 90° to piston pin axis. Cylinder bores should be
measured halfway down the cylinder bore and trans­
verse to the engine crankshaft center line.
Pistons and cylinder bores should be measured at
normal room temperature, 21°C (70°F).
FITTING RINGS (1) Measurement of end gaps:
(a) Measure piston ring gap 2 inches from bot­
tom of cylinder bore. An inverted piston can be used to push the rings down to ensure positioning
rings squarely in the cylinder bore before measur­ ing.
(b) Insert feeler stock in the gap. The compres­
sion ring gap should be between
0.254-0.508
mm

•

5.9L
ENGINE
9 - 97

DIAMETER
(D)
SHOULD
BE

0.0000-0.0152
mm

(0.0000-0.0006
in.
LARGER
THAN
(C)
98.704-98.831
mm

(3.886-3.891
in.]
FEELER
GAUGE

H-c -#-D

ELLIPTICAL
SHAPE
OF
THE
PISTON

SKIRT
SHOULD
BE
0.254-0.304
mm

(0.010-0.012
in.)
LESS AT
DIAMETER
(A)
THAN
ACROSS
THE
THRUST
FACES
AT
DIAMETER
(B).

J9309-9

Fig.
12
Piston
Measurements (0.010-0.020 inch). The second compression ring
gap should be between 0.508-0.762 mm (0.020-
0.030 inch). The oil ring gap should be 0.254-1.270
mm (0.010-0.050 inch).
(c) Rings with insufficient end gap may be prop­
erly filled to the correct dimension. Rings with ex­
cess gaps should not be used.
(2) Install rings and confirm ring side clearance: (a) Install oil rings being careful not to nick or
scratch the piston.
(b) Install the compression rings using Installa­
tion Tool C-4184. The top compression may be in­ stalled with either side up. The second compression
ring must be installed with the identification mark
face up (toward top of piston) and the chamfer should face down. An identification mark on the
ring is a drill point, a stamped letter "O", an oval depression or the word TOP.
(c) Measure side clearance between piston ring
and ring land (Fig. 13). Clearance should be 0.038-
0.076 mm (0.0015-0.0030 inch) for the compression

rings.
The steel rail oil ring should be free in groove, but should not exceed 0.203 mm (0.0080
inch) side clearance. (d) Pistons with insufficient or excessive side
clearance should be replaced. (3) Arrange ring gaps 90° apart as shown in Fig.

14.

CONNECTING ROD BEARINGS Fit all rods on a bank until completed. DO NOT al­
ternate from one bank to another, because connect­ ing rods and pistons are not interchangeable from
one bank to another.
GROOVE

J9209-136

Fig.
13
Measuring
Piston
Ring
Side
Clearance
OIL
RING

SPACER
GAP
TOP
COMPRESSION
RING
GAP
SECOND
COMPRESSION

RING
GAP

OIL
RING
RAIL
GAP (TOP) OIL
RING
RAIL

GAP
(BOTTOM)
J9309-80

Fig.
14 Proper
Ring
Installation

The bearing caps are not interchangeable and
should be marked at removal to ensure correct as­ sembly.
Each bearing cap has a small V-groove across the
parting face. When installing the lower bearing
shell, make certain that the V-groove in the shell is
in line with the V-groove in the cap. This provides
lubrication of the cylinder wall in the opposite bank.
The bearing shells must be installed so that the
tangs are in the machined grooves in the rods and
caps.

Limits of taper or out-of-round on any crankshaft
journals should be held to 0.025 mm (0.001 inch). Bearings are available in 0.025 mm (0.001 inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254
mm (0.010 inch) and 0.305 mm (0.012 inch) under­
size.
Install the bearings in pairs. DO NOT use a
new bearing half with an old bearing
half.
DO
NOT file the rods or bearing caps.
INSTALLATION (1) Be sure that compression ring gaps are stag­
gered so that neither is in line with oil ring rail gap.

(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located properly (Fig. 14).
(3) Immerse the piston head and rings in clean en­
gine oil. Slide Piston Ring Compressor Tool C-385
over the piston and tighten with the special wrench (part of Tool C-385). Be
sure position
of
rings does

not change
during this operation.

(4) Install connecting rod bolt protectors on rod

bolts,
the long protector should be installed on the numbered side of the connecting rod. (5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Be sure connecting rod and cylinder bore number are the same. Insert rod and piston into cylinder bore and
guide rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on crankshaft journal. (7) The notch or groove on top of piston must be
pointing toward front of engine. The larger chamfer of the connecting rod bore must be Installed toward
crankshaft journal fillet.
(8) Install rod caps. Install nuts on cleaned and
oiled rod bolts and tighten nuts to 61 N*m (45 ft. lbs.)
torque. (9) Install the oil pan.
(10) Install the cylinder head.
(11) Install the engine Into the vehicle.

CRANKSHAFT
A crankshaft which has undersize journals will be
stamped with 1/4 inch letters on the milled flat on
the No.3 crankshaft counterweight (Fig. 15). FOR EXAMPLE: R2 stamped on the No.3 crank­
shaft counterweight indicates that the No.2 rod jour­
nal is 0.025 mm (0.001 in) undersize. M4 indicates
that the No.4 main journal is 0.025 mm (0.001 in) undersize. R3 M2 indicates that the No.3 rod journal
and the No.2 main journal are 0.025 mm (0.001 In)
undersize. When a crankshaft is replaced, all main and con­
necting rod bearings should be replaced with new
bearings. Therefore, selective fitting of the bearings is not required when a crankshaft and bearings are
replaced.

REMOVAL
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear­
ing cap.
(3) Identify bearing caps before removal. Remove
bearing caps and bearings one at a time. (4) Lift the crankshaft out of the block.
(5) Remove and discard the crankshaft rear oil

seals.
(6) Remove and discard the front crankshaft oil
seal. Undersize Journal
Identification
Stamp

0.025
mm
(0.001
inch) (Rod)

0.025
mm
(0.001
inch) (Main)
R1-R2-R3
or R4

M1-AA2-M3-AA4
or AA5
V/
LETTERS—/R-l-2>
(ROD)
VM-WHMAIN)

J9309-52

Fig.
15 Location of Crankshaft
identification

INSPECTION
OF
JOURNALS
The crankshaft connecting rod and main journals
should be checked for excessive wear, taper and scor­
ing. The maximum taper or out-of-round on any
crankshaft journal is 0.025 mm (0.001 inch).
Journal grinding should not exceed 0.305 mm
(0.012 inch) under the standard journal diameter. DO
NOT grind thrust faces of No.3 main bearing. DO
NOT nick crank pin or bearing fillets. After grind­ ing, remove rough edges from crankshaft oil holes
and clean out all oil passages.

CAUTION:
After any journal
grind,
it is important

that
the
final
paper or cloth
polish
be in the
same
direction as the engine rotates.

INSTALLATION
(1) Lightly oil the new upper seal lips with engine

oil.
(2) Install the new upper rear bearing oil seal with
the yellow paint facing towards the rear of the en­
gine.

(3) Position the crankshaft into the cylinder block.
(4) Lightly oil the new lower seal lips with engine

oil.
(5) Install the new lower rear bearing oil seal into
the bearing cap with the yellow paint facing towards the rear of the engine. (6) Apply 5 mm (0.20 in) drop of Loctite 515, or
equivalent, on each side of the rear main bearing cap (Fig. 16). Do not over apply sealant or allow the seal­
ant to contact the rubber seal. Assemble bearing cap
to cylinder block immediately after sealant applica­
tion.
(7) To align the bearing cap, use cap slot, align­
ment dowel and cap bolts. Do not remove excess ma­
terial after assembly. Do not strike rear cap more
than 2 times for proper engagement.
(8) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately

•

5.9L ENGINE
9 - 99

BEARING
CAP
J9309-72

Fig.
16 Sealant Application to Bearing Cap tighten to 115 N-m (85 ft. lbs.) torque.
(9) Install oil pump.
(10) Apply Mopar Silicone Rubber Adhesive Seal­
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 17). Ap­
ply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the
oil pan seal groove. (11) Install new front crankshaft oil seal. (12) Immediately install the oil pan.

MOPAR SILICONE SEALANT

RUBBER
ADHESIVE APPLIED
Fig.
17
Apply
Sealant to Bearing Cap to
Block
Joint

CRANKSHAFT
MAIN BEARINGS
Bearing caps are not interchangeable and should
be marked at removal to ensure correct assembly. Upper and lower bearing halves are NOT inter­
changeable. Lower main bearing halves of No.2 and
4 are interchangeable. Upper and lower No.3 bearing halves are flanged
to carry the crankshaft thrust loads. They are NOT interchangeable with any other bearing halves in the
engine (Fig. 18). Bearing shells are available in stan­
dard and the following undersizes: 0.25 mm (0.001

inch),
0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm (0.010 inch) and 0.305 mm (0.012 inch). Never install an undersize bearing that will reduce
clearance below specifications.

Fig.
18 Main Bearing
Identification

REMOVAL (1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear­
ing cap. (3) Identify bearing caps before removal. Remove
bearing caps one at a time.
(4) Remove upper half of bearing by inserting
Crankshaft Main Bearing Remover/Installer Tool
C-3059 into the oil hole of crankshaft (Fig. 19).
(5) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.

Fig.
19 Upper Main Bearing
Removal
and
Installation
with
Tool C-3059

INSTALLATION
Only one main bearing should be selectively fitted
while all other main bearing caps are properly tight­ ened. All bearing capbolts removed during service
procedures are to be cleaned and oiled before instal­ lation.

9
- 100 5.9L
ENGINE

• When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side. (1) Start bearing in place, and insert Crankshaft
Main Bearing Remover/Installer Tool C-3059 into oil
hole of crankshaft (Fig. 16).
(2) Slowly rotate crankshaft counterclockwise slid­
ing the bearing into position. Remove Tool C-3059.
(3) Install the bearing cap. Clean and oil the bolts.
Tighten the capbolts to 115 N»m (85 ft. lbs.) torque.
(4) Install the oil pump.
(5) Install the oil pan.

CRANKSHAFT REAR
OIL
SEALS
The service seal is a 2 piece, viton seal. The upper
seal half can be installed with crankshaft removed
from engine or with crankshaft installed. When a
new upper seal is installed, install a new lower seal.
The lower seal half can only be installed with the
rear main bearing cap removed.
UPPER SEAL REPLACEMENT (CRANKSHAFT
REMOVED)
(1) Remove the crankshaft.
(2) Lightly oil the new upper seal lips with engine

oil.

(3) Install the new upper rear bearing oil seal with
the yellow paint facing towards the rear of the en­

gine.

(4) Position the crankshaft into the cylinder block.
(5) Lightly oil the new lower seal lips with engine

oil.

(6) Install the new lower rear bearing oil seal into
the bearing cap with the yellow paint facing towards
the rear of the engine.
(7) Apply 5 mm (0.20 in) drop of Loctite 515, or
equivalent, on each side of the rear main bearing cap (Fig. 16). Do not over apply sealant or allow the seal­
ant to contact the rubber seal. Assemble bearing cap
to cylinder block immediately after sealant applica­
tion.
(8) To align the bearing cap, use cap slot, align­
ment dowel and cap bolts. Do not remove excess ma­
terial after assembly. Do not strike rear cap more
than 2 times for proper engagement.
(9) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately
tighten to 115
Nth
(85 ft. lbs.) torque. (10) Install oil pump.
(11) Apply Mopar Silicone Rubber Adhesive Seal­
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 17). Ap­
ply enough sealant until a small amount is squeezed
out. Withdraw nozzle and wipe excess sealant off the
oil pan seal groove.
(12) Install new front crankshaft oil seal.
(13) Immediately install the oil pan. UPPER SEAL REPLACEMENT (CRANKSHAFT
INSTALLED)
(1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear­
ing cap. (3) Remove the rear main bearing cap. Remove
and discard the old lower oil seal. (4) Carefully remove and discard the old upper oil
seal. (5) Lightly oil the new upper seal lips with engine

oil.
To allow ease of installation of the seal, loosen at least the 2 main bearing caps forward of the rear
bearing cap.
(6) Rotate the new upper seal into the cylinder
block being careful not to shave or cut the outer sur­ face of the seal. To assure proper installation, use the installation tool provided with the kit. Install the
new seal with the yellow paint facing towards the
rear of the engine.
(7) Install the new lower rear bearing oil seal into
the bearing cap with the yellow paint facing towards
the rear of the engine.
(8) Apply 5 mm (0.20 in) drop of Loctite 515, or
equivalent, on each side of the rear main bearing cap (Fig. 16). Do not over apply sealant or allow the seal­
ant to contact the rubber seal. Assemble bearing cap
to cylinder block immediately after sealant applica­
tion. Be sure the yellow paint faces toward the rear of the engine.
(9) To align the bearing cap, use cap slot, align­
ment dowel and cap bolts. Do not remove excess ma­
terial after assembly. Do not strike rear cap more
than 2 times for proper engagement.
(10) Install the rear main bearing cap with cleaned
and oiled cap bolts. Alternately tighten ALL cap
bolts to 115 N*m (85 ft. lbs.) torque.
(11) Install oil pump.
(12) Apply Mopar Silicone Rubber Adhesive Seal­
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 17). Ap­
ply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the
oil pan seal groove.
(13) Immediately install the oil pan.
LOWER SEAL REPLACEMENT (1) Remove the oil pan.
(2) Remove the oil pump from the rear main bear­
ing cap. (3) Remove the rear main bearing cap and discard
the old lower seal. (4) Carefully install a new upper seal (refer to Up­
per Seal Replacement - Crankshaft Installed proce­ dure above). (5) Lightly oil the new lower seal lips with engine

oil.
(6) Install a new lower seal in bearing cap with
yellow paint facing the rear of engine.

•

5.9L ENGINE
9 - 101 (7) Apply 5 mm (0.20 in) drop of Loctite 515, or
equivalent, on each side of the rear main bearing cap (Fig. 16). Do not over apply sealant or allow the seal­
ant to contact the rubber seal. Assemble bearing cap
to cylinder block immediately after sealant applica­
tion.
(8) To align the bearing cap, use cap slot, align­
ment dowel and cap bolts. Do not remove excess ma­
terial after assembly. Do not strike rear cap more than 2 times for proper engagement.
(9) Install the rear main bearing cap with cleaned
and oiled cap bolts. Alternately tighten the cap bolts
to 115 N-m (85 ft. lbs.) torque.
(10) Install oil pump.
(11) Apply Mopar Silicone Rubber Adhesive Seal­
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 17). Ap­
ply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the
oil pan seal groove. (12) Immediately install the oil pan.

CYLINDER BLOCK
Remove the engine assembly from the vehicle.

DISASSEMBLE
(1) Remove the cylinder head. (2) Remove the oil pan.
(3) Remove the piston/connecting rod assembly.

CLEANING
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leaking.

INSPECTION
Examine block for cracks or fractures.
The cylinder walls should be checked for
out-of-

round and taper with Cylinder Bore Indicator Tool C-119. The cylinder block should be bored and honed
with new pistons and rings fitted if:
• The cylinder bores show more than 0.127 mm (0.005 inch) out-of-round.
• The cylinder bores show a taper of more than 0.254 mm (0.010 inch).
• The cylinder walls are badly scuffed or scored. Boring and honing operation should be closely co­
ordinated with the fitting of pistons and rings so specified clearances may be maintained.
Refer to Standard Service Procedures in the begin­
ning of this Group for the proper honing of cylinder

bores.

OIL LINE
PLUG The oil line plug is located in the vertical passage
at the rear of the block between the Oil-To-Filter and
Oil-From-Filter passages (Fig. 20). Improper installa­
tion or plug missing could cause erratic, low or no oil
pressure. (1) Remove oil pressure sending unit from back of
block. (2) Insert a 3.175 mm (1/8 inch) finish wire or
equivalent into passage.
(3) Plug should be 190.0 to 195.2 mm (7-1/2 to
7-11/16 inches) from machined surface of block (Fig.

20).
If plug is too high, use a suitable flat dowel drift
to position properly.

RIGHT OIL GALLERY

J9109-229

Fig.
20 Oil
Line
Plug

(4) If plug is off position, remove oil pan and rear
main bearing cap. Use suitable flat dowel to remove
plug. Coat outside diameter of plug, with Mopar (stud and bearing mount adhesive), or equivalent. Plug
should be 54.0 to 57.7 mm (2-1/8 to 2-5/16 inches)
from bottom of the block.
(5) Assemble engine and check oil pressure.

ENGINE CORE,
OIL AND
CAMSHAFT
PLUGS Engine core plugs have been pressed into the oil
galleries behind the camshaft thrust plate (Fig. 21).
This will reduce internal leakage and help maintain
higher oil pressure at idle.

RE10¥AL
(1) Using a blunt tool such as a drift or a screw­
driver and a hammer, strike the bottom edge of the
cup plug (Fig. 22).
(2) With the cup plug rotated, grasp firmly with
pliers or other suitable tool and remove plug (Fig.
22).

CLEANING
Thoroughly clean inside of cup plug hole in cylin­
der block or head. Be sure to remove old sealer.
Make certain the new plug is cleaned of all oil or
grease.

INSTALLATION
(1) Coat edges of plug and core hole with Mopar
Gasket Maker, or equivalent.

9
- 102 5.9L
ENGINE
— ^ ^ — — ^ — •
Fig. 21 Location of Cup
Plugs
in Oil Galleries

CAUTION:
DO NOT
drive
cup
plug
into the
casting

as
restricted coolant
flow can
result
and
cause
se­
rious
engine problems.
CYLINDER

Fig. 22 Core Hole
Plug
Removal
(2) Using proper drive plug, drive plug into hole.
The sharp edge of the plug should be at least 0.50 mm (0.020 inch) inside the lead-in chamfer.
It is not necessary to wait for curing of the sealant.
The cooling system can be filled and the vehicle
placed in service immediately.

ASSEMBLE
(1) Install the piston/connecting rod assembly.
(2) Install the oil pan.
(3) Install the cylinder head.
(4) Install the engine into the vehicle.

— 5.9L
ENGINE
9 - 103

SPECIFICATIONS—5.9L
ENGINE

EmmmE
SPECIFICATIONS
Camshaft
Bearing
Diameter
No i 50.800 - 50.825 mm "" (2.000 - 2.001 in)

No2
50.394-50.419 mm
' (1.984- 1.985 in)
No 3 50.013 - 50.038 mm
(1.969- 1 970 in)

No
4 49.606 - 49.632 mm
(1.953 - 1.954 in)

No
5 ................ 39.683 -39.713 mm

(1.5625-
1.5635 in)

Diametrical
Clearance 0.0254 - 0.0762 mm
(0.001 - 0.003 in)

Max.
Allowable
. 0.127 mm (0.005 in)

End
p|ay 0.051 - 0.254 mm
(0.002-0.010 in)
Bearinq
Journal
Diameter

No i 50.749 - 50.775 mm (1.998- 1.999 in)

No
2 50.343 - 50.368 mm
(1.982-
1.983 in)

No
3 . .............. 49.962 - 49.987 mm (1.967- 1.968 in)

No
4 . 49.555-49.581 mm
(1.951
- 1 952 in)

No
5 39.637 - 39.662 mm
(1.5605-
1.5615 in)
Connecting
Rods

Bearing Clearance 0.0127 - 0.0559 mm (0.0005 - 0.0022 in)
Piston Pin Bore
Diameter
24.966 - 24.978 mm
(0.9829 - 0.9834 in)

Side
Clearance (Two
Rods)
......................... 0.152 - 0.356 mm
(0.006-0.014 in)

Total
Weight
(Less
Bearing) . ... • 758 grams
(25.74 oz)
Crankshaft

Connecting
Rod
Journal
Diameter
. 53.950 - 53.975 mm (2.124 - 2.125 in)
Out-of-Round (Max.) 0.0254 mm
(0.001 in)
Taper (Max.) ... 0.0254 mm
(0.001 in)

Diametrical
Clearance

No
1
... ........ 0.0127 - 0.0381 mm (0.0005-0.0015 in)

Max
Allowable
(No.l)
- 0.0381 mm
(0.0015 in)

Nos.2,
3, 4 and 5 0.0127 - 0.0508 mm
(0.0005 - 0.0020 in)

Max.
Allowable
(Nos.2,
3, 4 & 5) ...... - 0.0635 mm (0.0025 in)
End
Play 0.051 -0.178 mm
(0.002 - 0.007 in)

Max.
Allowable
0.254 mm
(0.010 in)
Main Bearing Journals
Diameter
71.361 - 71.387 mm

(2.8095-
2.8105 in)
Out-of-Round (Max.) 0.0254 mm
(0.001 in)
Taper (Max.) .., 0.0254 mm
(0.001 in)
Cylinder Block

Cylinder
Bore
Diameter
, 101.60 - 101.65 mm (4.000 - 4.002 in)
Out-of-Round (Max.) ........... 0.127 mm
(0.005 in)
Taper (Max.) 0.254 mm
(0.010 in)

Distributor
Lower
Drive
Shaft
Bushing (Press Fit in Block) 0.0127 - 0.3556 mm (0.0005-0.0140 in)
Shaft-to-Bushing Clearance 0.0178 - 0.0686 mm (0.0007 - 0,0027 in)

Tappet
Bore
Diameter
.............. 22.99 - 23.01 mm (0.9051 - 0.9059 in)
Cylinder Head
Compression Pressure 689 kPa (100 psi)
Gasket Thickness (Compressed)
1.2065
mm
(0.0475 In)
Valve Seat
Angle .
44.25°
- 44.75° Runout (Max.) ....................... 0.0762 mm (0.003 in)

Width
(Finish) -
Intake
1.016-1.524
mm (0,040-0.060 in)

Width
(Finish) - Exhaust
1.524-2.032
mm
(0.060-0.080
in)
Hydraulic Tappets
Body
Diameter
22.949 - 22.962 mm (0.9035 - 0.9040 in)
Clearance in Block 0.0279 - 0.0610 mm
(0.0011 - 0.0024 in)
Dry
Lash
. 1.524 - 5.334 mm
(0.060-0210 in)

Push
Rod
Length
190.63 - 191.14mm
(7.505 - 7.525 in)
J9309-102

9 - 104 5.9L ENGINE
• ENGINE
SPECIFICATIONS
(CONT„)

Oil
Pump

Clearance over Rotors (Max.) 0.1016 mm (0.004 in)
Cover Out-of-Flat (Max.)
0.0381
mm (0.0015 in)
Inner Rotor Thickness (Min.) 20.955 mm
(0.825 in)
Outer Rotor
Clearance (Max.) 0.3556 mm (0.014 in)
Diameter (Min.) 62.7126 mm (2.469 in)
Thickness (Min.) 20.955 mm (0.825 in)
Tip Clearance between Rotors (Max.) 0.2032 mm (0.008 in)
Oil
Pressure

At Curb Idle Speed
*
41.4 kPa (6 psi)

At
3000 rpm 207 - 552 kPa (30 - 80 psi)
Switch Actuating Pressure (Min.) 34.5 - 48.3 kPa (5-7 psi)
* CAUTION: If pressure is ZERO at curb idle, DO NOT run engine at
3,000
rpm.
Oil
Filter
Bypass Valve Setting 62 -103 kPa (9-15 psi)
Pistons
Clearance at
Top
of Skirt 0.0127
-
0.0381
mm (0.0005-0.0015 in)
Land Clearance (Diametrical)
0.508
-
0.660
mm (0.020 -
0.026
in)
Piston Length 81.03 mm (3.19 in)
Piston Ring Groove Depth
Nos.l and 2 4.761 -4.912 mm (0.187-0.193 in)
No.3 3.996-4.177
mm
(0.157-0.164 in)
Weight 582 - 586 grams (20.53 - 20.67 oz)

Piston
Pins

Clearance In Piston
0.006
- 0.019 mm (0.00023 - 0.00074 in)
Diameter 25.007
-
25.015 mm
(0.9845 - 0.9848 in)
End Play NONE
Length 67.8 - 68.3 mm (2.67
-
2.69 in)
Piston
Rings
Ring Gap
Compression Ring (Top) 0.30 - 0.55 mm (0.012-0.022 in)
Compression Rings (2nd) 0.55 - 0.80 mm (0.022 - 0.031 in)
Oil Control (Steel Rails) 0.381 - 1.397 mm (0.015-0.055 in)
Ring Side Clearance Compression Rings
0.040
-
0.085
mm (0.0016-0.0033 in)
Oil Ring (Steel Rails) 0.05 - 0.21 mm (0.002 -
0.008
in)
Ring Width Compression Rings 1.530 - 1.555 mm (0.060 - 0.061 in)
Oil Ring (Steel Rails) - Max
0.447
-
0.473
mm (0.018-0.019 in)

Valves

Face Angle 43.25° - 43.75°
Head Diameter Intake 47.752 mm (1.88 in)
Exhaust 41.072 mm
(1.617 in)
Length (Overall) Intake 126.21 - 126.85 mm
(4.969 - 4.994 in)
Exhaust 126.44 - 127.30 mm
(4.978-5.012 in)
Lift (Zero Lash) 10.414 mm
(0.410 in)
Stem Diameter Intake
9.449
-
9.474
mm
(0.372 -
0.373
in)
Exhaust
9.423
-
9.449
mm
(0.371 -
0.372
in)
Stem-to-Guide Clearance Intake 0.0254 - 0.0762 mm (0.001 -
0.003
in)
Exhaust 0.0508-0.1016 mm
(0.002 -
0.004
in)
Max. Allowable (Rocking Method) 0.4318 mm (0.017 in)
Guide Bore Diameter (Std)
9.500
-
9.525
mm (0.374 -
0.375
in) J9309-103

5.9L
ENGINE
9 - 105

ENGINE SPECIFICATIONS
(CONT.J

Valve
Springs
Free Length
(Approx.)...........
49.962
mm f1.967 in)

Spring
Tension ................ @ 41.66 mm = 378 N
(Valve Closed) (@ 1.64 in « 85 lbs)

Spring
Tension @ 30.89 mm = 890 N (Valve Open) (@ 1.212 in = 200 lbs)
Number of Coils ............... 6.8
Installed Height 41.66 mm (Spring Seat to Retainer) (1.64 in)
Wire Diameter ................ 4.50 mm

(0.177
in) Valve
Timing

Exhaust
Valve

Closes
(ATC) ............. 16°

Opens
(BBC) .................. ....... 52° Duration 248°
Intake Valve
Closes
(ABC) 50°

Opens
(BTC) 10° Duration ................. 240°
Valve Overlap.............................. 26°

J9309-33

OVERSIZE
AND
UNDERSIZE
ENGINE COMPONENT MARKINGS
CONDITION

IDENTIFICATION
LOCATION
OF
IDENTIFICATION

0.025
mm
(0.001
inch)
U/S
Crankshaft
RorM

M-2-3 etc. (Indicating No. 2 & 3 main bearing journal)

and/or
R-l-4 etc. (Indicating No. 1 & 4 connecting
rod journal) Milled
flat
on number
three
crankshaft
counterweight

0.508
mm
(0.020
inch)
O/S
Cylinder Bores
A

Following engine serial number.

0.203
mm
(0.008
inch)

O/S
Tappets • 3/8" diamond-shaped stamp Top pad — Front
of engine and
flat
ground on outside surface of
each O/S tappet bore.
0.127 mm
(0.005
inch)

O/S
Valve Stems
X

Milled pad adjacent to two 3/8" tapped holes

on
each end of cylinder head.

J9209-120