service DODGE DURANGO 1998 1.G Repair Manual

Downloaded from www.Manualslib.com manuals search engine inch). The width of the exhaust seats should be
1.524-2.032 mm (0.060-0.080 inch).
VALVE SPRING INSPECTION
Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested. As an example the compression length of
the spring to be tested is 1-5/16 inch. Turn table of
Universal Valve Spring Tester Tool until surface is in
line with the 1-5/16 inch mark on the threaded stud.
Be sure the zero mark is to the front (Fig. 23). Place
spring over stud on the table and lift compressing
lever to set tone device. Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by 2. This will give the
spring load at test length. Fractional measurements
are indicated on the table for finer adjustments.
Refer to specifications to obtain specified height and
allowable tensions. Discard the springs that do not
meet specifications.
MEASURING TIMING CHAIN STRETCH
NOTE: To access timing chain Refer to Timing
Chain Cover in Removal and Installation Section.
(1) Place a scale next to the timing chain so that
any movement of the chain may be measured.
(2) Place a torque wrench and socket over cam-
shaft sprocket attaching bolt. Apply torque in the
direction of crankshaft rotation to take up slack; 41
N´m (30 ft. lbs.) torque with cylinder head installed
or 20 N´m (15 ft. lbs.) torque with cylinder head
removed. With a torque applied to the camshaftsprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block the crankshaft to
prevent rotation.
(3) Hold a scale with dimensional reading even
with the edge of a chain link. With cylinder heads
installed, apply 14 N´m (30 ft. lbs.) torque in the
reverse direction. With the cylinder heads removed,
apply 20 N´m (15 ft. lbs.) torque in the reverse direc-
tion. Note the amount of chain movement (Fig. 24).
(4) Install a new timing chain, if its movement
exceeds 3.175 mm (1/8 inch).
(5) If chain is not satisfactory, remove camshaft
sprocket attaching bolt and remove timing chain with
crankshaft and camshaft sprockets.
(6) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores.
Fig. 22 Refacing Valve Seats
1±STONE
2 ± PILOT
3 ± VALVE SEAT
4 ± SHROUD
Fig. 23 Testing Valve Spring for Compressed
Length
1 ± TORQUE WRENCH
2 ± VALVE SPRING TESTER
Fig. 24 Measuring Timing Chain Wear and Stretch
1 ± TORQUE WRENCH
2 ± 3.175 MM
(0.125 IN.)
DN5.9L ENGINE 9 - 155
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine (7) Place timing chain around both sprockets.
(8) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam-
shaft sprocket.
(9) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(10) Slide both sprockets evenly over their respec-
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 25).
(11) Install the camshaft bolt. Tighten the bolt to
47 N´m (35 ft. lbs.) torque.
(12) Check camshaft end play. The end play should
be 0.051-0.152 mm (0.002-0.006 inch) with a new
thrust plate and up to 0.254 mm (0.010 inch) with a
used thrust plate. If not within these limits install a
new thrust plate.
PISTONSÐFITTING
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) at
21ÉC (70ÉF).
Piston diameter should be measured at the top of
skirt, 90É 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, 21ÉC (70ÉF).
Check the pistons for taper and elliptical shape
before they are fitted into the cylinder bore (Fig. 26).
PISTON RINGSÐFITTING
(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 gauge in the gap. The top com-
pression ring gap should be between 0.254-0.508
mm (0.010-0.020 inch). The second compressionring 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 filed to the correct dimension. Rings with
excess 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. Install the oil control rings
according to instructions in the package. It is not
necessary to use a tool to install the upper and
lower rails. Insert oil rail spacer first, then side
rails.
(b) Install the second compression rings using
Installation Tool C-4184. The compression rings
must be installed with the identification mark face
up (toward top of piston) and chamfer facing down.
An identification mark on the ring is a drill point,
a stamped letter ªOº, an oval depression or the
word TOP (Fig. 27) (Fig. 29).
(c) Using a ring installer, install the top com-
pression ring with the chamfer facing up (Fig. 28)
(Fig. 29). An identification mark on the ring is a
drill point, a stamped letter ªOº, an oval depression
or the word TOP facing up.
(d) Measure side clearance between piston ring
and ring land. Clearance should be 0.074-0.097 mm
(0.0029-0.0038 inch) for the compression rings. The
steel rail oil ring should be free in groove, but
should not exceed 0.246 mm (0.0097 inch) side
clearance.
(e) Pistons with insufficient or excessive side
clearance should be replaced.
Fig. 25 Alignment of Timing Marks
1 ± TIMING MARKS
Fig. 26 Piston Measurements
1 ± 49.53 mm
(1.95 IN.)
9 - 156 5.9L ENGINEDN
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine CONNECTING ROD BEARINGSÐFITTING
Fit all rods on a bank until completed. DO NOT
alternate from one bank to another, because connect-
ing rods and pistons are not interchangeable from
one bank to another.
The bearing caps are not interchangeable and
should be marked at removal to ensure correct
assembly.
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 lubrica-
tion 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.
CRANKSHAFT MAIN BEARINGSÐFITTING
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.
PISTON MEASUREMENT CHART
PISTON A DIA = PISTON BORE
SIZE DIAMETER DIAMETER
MIN. MAX. MIN. MAX.
mm
(in.)mm
(in.)mm
(in.)mm (in.)
AÐÐÐ Ð
B101.580 101.592 101.605 101.618
(3.9992) (3.9997) (4.0002) (4.0007)
C101.592 101.605 101.618 101.630
(3.9997) (4.0002) (4.0007) (4.0012)
D101.605 101.618 101.630 101.643
(4.0002) (4.0007) (4.0012) (4.0017)
EÐÐÐ Ð
DESCRIPTION SPECIFICATION
PISTON PIN BORE 25.007 - 25.015 mm
(.9845 -.9848 in.)
RING GROOVE
HEIGHT
OIL RAIL 4.033 - 4.058 mm
(.1588 -.1598 in.)
COMPRESSION
RAIL1.529 - 1.554 mm
(.0602 -.0612 in.)
TOTAL FINISHED 470.862 grams
WEIGHT (16.6076.0706 ounces)
Fig. 27 Second Compression Ring Identification
(Typical)
1 ± SECOND COMPRESSION RING (BLACK CAST IRON)
2 ± CHAMFER
3 ± TWO DOTS
Fig. 28 Top Compression Ring Identification
(Typical)
1 ± TOP COMPRESSION RING (GRAY IN COLOR)
2 ± CHAMFER
3 ± ONE DOT
DN5.9L ENGINE 9 - 157
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine 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. 31). 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.
REMOVAL AND INSTALLATION
ENGINE FRONT MOUNTS
REMOVALÐ2WD
(1) Disconnect the negative cable from the battery.
(2) Raise hood and position fan to assure clearance
for radiator top tank and hose.
CAUTION: DO NOT lift the engine by the intake
manifold.
(3) Install engine lifting fixture.
(4) Raise vehicle on hoist.
(5) Remove the insulator through bolt (Fig. 32)
(Fig. 33).
(6) Raise engine with lifting fixture SLIGHTLY.
Remove insulator retaining bolts and remove the
insulator assembly.
(7) Remove insulator heat shield and transfer to
new insulator.
INSTALLATIONÐ2WD
(1) With the engine raised SLIGHTLY, position
insulator assembly onto the engine block and install
bolts (Fig. 32) (Fig. 33). Tighten the bolts to 41 N´m
(30 ft. lbs.) torque.
(2) Lower engine with lifting fixture while guiding
insulator assembly into the engine insulator bracket
(Fig. 34).
(3) Install insulator to bracket thru-bolt. Tighten
the thru-bolt nut to 68 N´m (50 ft. lbs.) torque.
(4) Remove lifting fixture.
(5) Connect the negative cable to the battery.
Fig. 29 Compression Ring Chamfer Location
(Typical)
1 ± CHAMFER
2 ± TOP COMPRESSION RING
3 ± SECOND COMPRESSION RING
4 ± PISTON
5 ± CHAMFER
Fig. 30 Proper Ring Installation
1 ± OIL RING SPACER GAP
2 ± SECOND COMPRESSION RING GAP OIL RING RAIL GAP
(TOP)
3 ± OIL RING RAIL GAP (BOTTOM)
4 ± TOP COMPRESSION RING GAP
Fig. 31 Main Bearing Identification
9 - 158 5.9L ENGINEDN
SERVICE PROCEDURES (Continued)

Downloaded from www.Manualslib.com manuals search engine REMOVALÐ4WD
On 4WD vehicles the engine front support brackets
attach directly to engine block and the axle housing.
The brackets provide a solid interconnection for these
units (Fig. 35) (Fig. 36). Engine must be supported
during any service procedures involving the front
support assemblies.
(1) Disconnect the negative cable from the battery.
(2) Raise vehicle on hoist.
(3) Install engine lifting (support) fixture.
(4) Remove front axle. (Refer to Group 3, Differen-
tial and Driveline in this publication.)
(5)Left mount insulator only.Remove starter
wires and starter motor assembly.
(6) Remove insulator to frame through bolt (Fig.
37).
(7) Raise engine slightly.
(8) Remove upper insulator to support bracket
stud nut and insulator to support through bolt.
(9) Remove engine mount insulator (Fig. 35) (Fig.
36).
(10) If engine support bracket is to be removed/re-
placed, remove support bracket to transmission bell
housing bolt(s) and three (3) support bracket to
engine block bolts. Remove support bracket (Fig. 35)
(Fig. 36).
Fig. 32 Engine Right Front Insulator MountÐ2WD
Vehicles
1 ± HEAT SHIELD
2 ± INSULATOR
Fig. 33 Engine Left Front Insulator MountÐ2WD
Vehicles
1 ± HEAT SHIELD
2 ± INSULATOR
Fig. 34 Engine Mount Insulator at Frame
1 ± NUT
2 ± INSULATOR
3 ± FRAME
4 ± THROUGH BOLT
DN5.9L ENGINE 9 - 159
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine CRANKSHAFT MAIN BEARINGS
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. 67).
(5) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
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.
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. 67).
(2) Slowly rotate crankshaft counterclockwise slid-
ing the bearing into position. Remove Tool C-3059.
(3) Install the bearing caps. 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.
(6) Start engine check for leaks.
OIL PAN
REMOVAL
2WD
(1) Disconnect the negative cable from the battery.
(2) Remove air cleaner assembly.
(3) Remove engine oil dipstick.(4) Disconnect distributor cap and position away
from cowl.
(5) Remove the fan shroud. Refer to COOLING
SYSTEM.
(6) Disconnect throttle valve cable from throttle
body and mounting bracket (Fig. 67A).
(7) Raise vehicle.
(8) Drain engine oil.
(9) Remove exhaust pipe from exhaust manifolds.
(10) Remove engine mount insulator through bolts.
(11) Raise engine by way of oil pan using a block of
wood between the jack and oil pan.
(12) When engine is high enough, place mount
through bolts in the engine mount attaching points on
the frame brackets.
(13) Lower engine so bottom of engine mounts rest
on the replacement bolts placed in the engine mount
frame brackets.
(14) Remove transmission to engine braces.
(15) Remove starter. Refer to STARTING SYS-
TEMS.
(16) Remove transmission torque converter inspec-
tion cover.
(17) Disconnect rear support cushion from cross-
member.
(18) Raise rear of transmission away from cross-
member.
(19) Remove oil pan and one-piece gasket.
4WD
(1) Disconnect the negative cable from the battery.
(2) Remove engine oil dipstick.
(3) Raise vehicle.
(4) Drain engine oil.
(5) Remove front driving axle. Refer to DIFFEREN-
TIAL and DRIVELINE.
(6) Remove both engine mount support brackets.
(7) Remove transmission torque converter inspec-
tion cover.
(8) Remove oil pan and one-piece gasket.
Fig. 67 Upper Main Bearing Removal and
Installation with Tool C-3059
1 ± SPECIAL TOOL C-3059
2 ± BEARING
3 ± SPECIAL TOOL C-3059
4 ± BEARING
Fig. 67A Throttle Valve Cable Removal/Installation
1 ± TRANSMISSION THROTTLE VALVE CABLE BRACKET
2 ± AIR INLET DUCT
3 ± TRANSMISSION THROTTLE VALVE CABLE
9 - 174 5.9L ENGINEDN
REMOVAL AND INSTALLATION (Continued)
2000 DN Service Manual
Publication No. 81-370-0016
TSB 26-12-99 December, 1999

Downloaded from www.Manualslib.com manuals search engine INSTALLATION
2WD
(1) Fabricate 4 alignment dowels from 5/16x11/2
inch bolts. Cut the head off the bolts and cut a slot
into the top of the dowel. This will allow easier instal-
lation and removal with a screwdriver (Fig. 68).
(2) Install the dowels in the cylinder block (Fig. 69).
(3) Apply small amount of Mopar Silicone Rubber
Adhesive Sealant, or equivalent in the corner of the
cap and the cylinder block.
(4) Slide the one-piece gasket over the dowels and
onto the block.
(5) Position the oil pan over the dowels and onto
the gasket.
(6) Install the oil pan bolts. Tighten the bolts to 24
N´m (215 in. lbs.) torque.
(7) Remove the dowels. Install the remaining oil
pan bolts. Tighten these bolts to 24 N´m (215 in. lbs.)
torque.
(8) Install the drain plug. Tighten drain plug to 34
N´m (25 ft. lbs.) torque.
(9) Lower transmission onto crossmember.
(10) Install rear support cushion mounting bolts.
Tighten bolts 28 N´m (250 in. lbs.).
(11) Raise engine by way of oil pan with a wood
block placed between jack and oil pan.(12) Remove through bolts from frame brackets
and lower engine. Install mount insulator through
bolts and tighten to 95 N´m (70 ft. lbs.).
(13) Install starter.
(14) Install transmission torque converter inspec-
tion cover.
(15) Install engine to transmission braces.
(16) Install exhaust pipe.
(17) Lower vehicle.
(18) Position throttle valve cable into bracket, then
attach to throttle body (Fig. 67A).
(19) Connect the distributor cap.
(20) Install dipstick.
(21) Install fan shroud.
(22) Install air cleaner assembly.
(23) Connect the negative cable to the battery.
(24) Fill crankcase with oil to proper level.
4WD
(1) Fabricate 4 alignment dowels from 1 1/2 x 5/16
inch bolts. Cut the head off the bolts and cut a slot
into the top of the dowel. This will allow easier instal-
lation and removal with a screwdriver (Fig. 68).
(2) Install the dowels in the cylinder block (Fig. 69).(3) Apply small amount of Mopar Silicone Rubber
Adhesive Sealant, or equivalent in the corner of the
cap and the cylinder block.
(4) Slide the one-piece gasket over the dowels and
onto the block.
(5) Position the oil pan over the dowels and onto
the gasket.
(6) Install the oil pan bolts. Tighten the bolts to 24
N´m (215 in. lbs.) torque.
(7)
Remove the dowels. Install the remaining oil pan
bolts. Tighten these bolts to 24 N´m (215 in. lbs.) torque.
(8) Install the drain plug. Tighten drain plug to 34
N´m (25 ft. lbs.) torque.
(9) Install transmission inspection cover.
(10) Install engine mount support brackets and
insulators.
(11) Install front drive axle. Refer to DIFFEREN-
TIAL and DRIVELINE.
(12) Lower vehicle
(13) Connect the distributor cap.
(14) Install dipstick.
(15) Connect the negative cable to the battery.
(16) Fill crankcase with oil to proper level.
PISTON AND CONNECTING ROD ASSEMBLY
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 a reli-
able ridge reamer before removing pistons from cylin-
der 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, rotate crankshaft to center
the connecting rod in the cylinder bore and at BDC.
Be careful not to nick crankshaft journals.
(7) After removal, install bearing cap on the mating rod.
Fig. 68 Fabrication of Alignment Dowels
1 ± 1 1/2º x 5/16º BOLT
2 ± DOWEL
3 ± SLOT
Fig. 69 Position of Dowels in Cylinder Block
1 ± DOWEL
2 ± DOWEL
3 ± DOWEL
4 ± DOWEL
DN5.9L ENGINE 9 - 175
REMOVAL AND INSTALLATION (Continued)
2000 DN Service Manual
Publication No. 81-370-0016
TSB 26-12-99 December, 1999

Downloaded from www.Manualslib.com manuals search engine CRANKSHAFT OIL SEALSÐREAR
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 ÐCRANKSHAFT REMOVED
REMOVAL
(1) Remove the crankshaft. Discard the old upper
seal.
INSTALLATION
(1) Clean the cylinder block rear cap mating sur-
face. Make sure the seal groove is free of debris.
(2) Lightly oil the new upper seal lips with engine
oil.
(3) Install the new upper rear bearing oil seal with
the white paint facing towards the rear of the engine.
(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 white paint facing towards
the rear of the engine.
(7) Apply 5 mm (0.20 in) drop of MopartGasket
Maker, or equivalent, on each side of the rear main
bearing cap (Fig. 77). DO NOT over apply sealant or
allow the sealant to contact the rubber seal. Assem-
ble bearing cap to cylinder block immediately after
sealant application.(8) To align the bearing cap, use cap slot, align-
ment dowel and cap bolts. DO NOT remove excess
material 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 N´m (85 ft. lbs.) torque.
(10) Install oil pump.
(11) Apply MopartSilicone Rubber Adhesive Seal-
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 78).
Apply enough sealant until a small amount is
squeezed out. Withdraw nozzle and wipe excess seal-
ant off the oil pan seal groove.
(12) Install new front crankshaft oil seal.
(13) Immediately install the oil pan.
UPPER SEAL ÐCRANKSHAFT INSTALLED
REMOVAL
(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.
INSTALLATION
(1) Clean the cylinder block mating surfaces before
oil seal installation. Check for burr at the oil hole on
the cylinder block mating surface to rear cap.
(2) Lightly oil the new upper seal lips with engine
oil. To allow ease of installation of the seal, loosen at
Fig. 77 Sealant Application to Bearing Cap
1 ± MOPAR SILICONE RUBBER ADHESIVE SEALANT SLOTS
2 ± LOCTITE 518 (OR EQUIVALENT)
3 ± CAP ALIGNMENT SLOT
4 ± REAR MAIN BEARING CAP
Fig. 78 Apply Sealant to Bearing Cap to Block Joint
1 ± MOPAR SILICONE RUBBER ADHESIVE SEALANT NOZZLE
TIP
2 ± SEALANT APPLIED
3 ± CYLINDER BLOCK
4 ± REAR MAIN BEARING CAP
DN5.9L ENGINE 9 - 179
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine INSTALLATION
Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.
Be certain the new plug is cleaned of all oil or
grease.
(1) Coat edges of plug and core hole with Mopart
Gasket Maker, or equivalent.
CAUTION: DO NOT drive cup plug into the casting,
as restricted coolant flow can result and cause seri-
ous engine problems.
(2) Using proper plug drive, drive cup plug into
hole. The sharp edge of the plug should be at least
0.50 mm (0.020 in.) inside the lead-in chamfer.
(3) It is not necessary to wait for curing of the
sealant. The cooling system can be filled and the
vehicle placed in service immediately.
DISASSEMBLY AND ASSEMBLY
OIL PUMP
DISASSEMBLE
(1) Remove the relief valve as follows:
(a) Remove cotter pin. Drill a 3.175 mm (1/8
inch) hole into the relief valve retainer cap and
insert a self-threading sheet metal screw.
(b) Clamp screw into a vise and while support-
ing oil pump, remove cap by tapping pump body
using a soft hammer. Discard retainer cap and
remove spring and relief valve (Fig. 81).(2) Remove oil pump cover (Fig. 82).
(3) Remove pump outer rotor and inner rotor with
shaft (Fig. 82).
(4) Wash all parts in a suitable solvent and inspect
carefully for damage or wear.
Fig. 80 Core Hole Plug Removal
1 ± CYLINDER BLOCK
2 ± REMOVE PLUG WITH PLIERS
3 ± STRIKE HERE WITH HAMMER
4 ± DRIFT PUNCH
5 ± CUP PLUGFig. 81 Oil Pressure Relief Valve
1 ± OIL PUMP ASSEMBLY
2 ± COTTER PIN
3 ± RELIEF VALVE
4 ± RETAINER CAP
5 ± SPRING
Fig. 82 Oil Pump
1 ± INNER ROTOR AND SHAFT
2 ± BODY
3 ± DISTRIBUTOR DRIVESHAFT (REFERENCE)
4 ± COTTER PIN
5 ± RETAINER CAP
6 ± SPRING
7 ± RELIEF VALVE
8 ± LARGE CHAMFERED EDGE
9 ± BOLT
10 ± COVER
11 ± OUTER ROTOR
DN5.9L ENGINE 9 - 181
REMOVAL AND INSTALLATION (Continued)

Downloaded from www.Manualslib.com manuals search engine CYLINDER BLOCK
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:
²The cylinder bores show more than 0.127 mm
(0.005 inch) out-of-round.
²The cylinder bores show a taper of more than
0.254 mm (0.010 inch).
²The cylinder walls are badly scuffed or scored.
Boring and honing operation should be closely coor-
dinated with the fitting of pistons and rings so spec-
ified clearances may be maintained.
Refer to Standard Service Procedures in the begin-
ning of this Group for the proper honing of cylinder
bores.
INTAKE MANIFOLD
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
The plenum pan rail must be clean and dry (free of
all foreign material).
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straightedge.
EXHAUST MANIFOLD
CLEANING
Clean mating surfaces on cylinder head and mani-
fold, wash with solvent and blow dry with com-
pressed air.
INSPECTION
Inspect manifold for cracks, Inspect mating sur-
faces of manifold for flatness with a straight edge.
Seal surfaces must be flat within 0.1 mm (0.004 inch)
overall.
SPECIFICATIONS
5.9L ENGINE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Engine Type 90É V-8 OHV
Bore and Stroke 101.6 x 90.9 mm
(4.00 x 3.58 in.)
Displacement 5.9L (360 c.i.)
Compression Ratio 9.1:1
Firing Order 1±8±4±3±6±5±7±2
Lubrication Pressure Feed ±
Full Flow Filtration
Cooling System Liquid Cooled ±
Forced Circulation
Cylinder Block Cast Iron
Cylinder Head Cast Iron
Crankshaft Nodular Iron
Camshaft Nodular Cast Iron
Combustion Chambers Wedge -
High Swirl Valve
Shrouding
Pistons Aluminum Alloy w/strut
Connecting Rods Forged Steel
Cylinder Compression 689.5 kPa
Pressure (Min.) (100 psi)
DESCRIPTION SPECIFICATION
CAMSHAFT
Bearing Diameter
No. 1 50.800 ± 50.825 mm
(2.000 ± 2.001 in.)
No. 2 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 39.688 ± 39.713 mm
(1.5625 ± 1.5635 in.)
DN5.9L ENGINE 9 - 185
CLEANING AND INSPECTION (Continued)