Page 1 DODGE RAM 1500 1998 2.G Owners Manual

Component Page
Speaker-Right Instrument Panel....... 8W-80-96
Speaker-Right Rear................. 8W-80-96
Speed Control Servo (Diesel A/T/NGC) . . . 8W-80-97
Speed Control Switch-Left (ETC)....... 8W-80-97
Speed Control Switch-Left
(Except ETC).................... 8W-80-97
Speed Control Switch-Right (ETC)...... 8W-80-97
Speed Control Switch-Right (Except
ETC)........................... 8W-80-97
Tail/Stop/Turn Signal Lamp-Left....... 8W-80-98
Tail/Stop/Turn Signal Lamp-Right...... 8W-80-98
Tailgate Lamp..................... 8W-80-98
Throttle Position Sensor (3.7L)......... 8W-80-98
Throttle Position Sensor (4.7L)......... 8W-80-99
Tow/haul Overdrive Switch............ 8W-80-99
Trailer Tow Connector............... 8W-80-99
Trailer Tow Connector-Add On......... 8W-80-99
Transfer Case Control Module C1 (Electric
4x4).......................... 8W-80-100
Transfer Case Control Module C2 (Electric
4x4).......................... 8W-80-100Component Page
Transfer Case Control Module C3
(Electric 4x4)................... 8W-80-101
Transfer Case Mode Sensor.......... 8W-80-101
Transfer Case Selector Switch........ 8W-80-101
Transfer Case Shift Motor........... 8W-80-101
Transmission Range Sensor.......... 8W-80-102
Transmission Solenoid Assembly
(48RE)........................ 8W-80-102
Transmission Solenoid/TRS Assembly
(NGC)......................... 8W-80-102
Vacuum Pump (Diesel).............. 8W-80-103
Vistronic Fan Drive (Diesel).......... 8W-80-103
Washer Fluid Level Switch........... 8W-80-103
Washer Pump Motor-Front........... 8W-80-103
Water In Fuel Sensor............... 8W-80-103
Wheel Speed Sensor-Left Front....... 8W-80-104
Wheel Speed Sensor-Rear............ 8W-80-104
Wheel Speed Sensor-Right Front...... 8W-80-104
Wiper Motor...................... 8W-80-104
8W - 80 - 4 8W-80 CONNECTOR PIN-OUTSDR

8W-91 CONNECTOR/GROUND/SPLICE LOCATION
TABLE OF CONTENTS
page
CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION..........................1
CONNECTOR/GROUND/SPLICE
LOCATION
DESCRIPTION
This section provides illustrations identifying con-
nector, ground, and splice locations in the vehicle.
Connector, ground, and splice indexes are provided.Use the wiring diagrams in each section for connec-
tor, ground, and splice identification. Refer to the
index for the proper figure number. For items that
are not shown in this section N/S is placed in the
Fig. column.
CONNECTORS
CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
4WD Switch (Manual Transfer
Case)BK Near T/O for Backup Lamp Switch 16, 17, 19
A/C Compressor Clutch BK At A/C Compressor 3, 6, 7, 10
A/C Pressure Transducer BK Left Side of A/C Compressor 6, 7, 10
A/C-Heater Control C1 BK Center of Instrument Panel 34, 35, 36
A/C-Heater Control C2 BK Center of Instrument Panel 34, 35
Accelerator Pedal Position Sensor Under Battery Tray 22, 27
Adjustable Pedal Motor WT Left of Instrument Panel 31
Adjustable Pedal Switch BL Left of Instrument Panel 35, 38
Airbag Control Module C1 YL Lower Center of Instrument Panel 35, 36
Airbag Control Module C2 YL Lower Center of Instrument Panel 44, 46
Airbag Control Module-Left Side
ImpactYL Left B-Pillar 44, 46
Airbag Control Module-Right Side
ImpactYL Right B-Pillar 45, 47
Airbag-Driver Squib 1 YL On Steering Wheel N/S
Airbag-Left Curtain YL Top Left B-Pillar 44, 46
Airbag-Passenger YL Right Front of Instrument Panel 35, 39
Airbag-Right Curtain YL Top Right B-Pillar 45, 47
Ambient Temperature Sensor BK Left Rear of Hood 23, 29
Amplifier Audio C1 GY Top Center of Instrument Panel 35, 39
Amplifier Audio C2 GY Top Center of Instrument Panel 35, 39
Ashtray Lamp Center Stack 35
Automatic Day/Night Mirror (Except
Base)BK Top Center of Windshield N/S
Backup Lamp Switch BK Left Rear of Transmission 12, 13, 17, 19
DR8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 1

8W-97 POWER DISTRIBUTION
TABLE OF CONTENTS
page page
POWER DISTRIBUTION
DESCRIPTION..........................1
OPERATION............................1
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS.........2
CIGAR LIGHTER OUTLET
DESCRIPTION..........................2
OPERATION............................2
DIAGNOSIS AND TESTING - CIGAR LIGHTER
OUTLET.............................2
INTEGRATED POWER MODULE
DESCRIPTION..........................3
OPERATION............................3
REMOVAL.............................3
INSTALLATION..........................4
FRONT CONTROL MODULE
DESCRIPTION..........................5OPERATION............................5
DIAGNOSIS AND TESTING - FRONT
CONTROL MODULE....................5
REMOVAL.............................6
INSTALLATION..........................6
IOD FUSE
DESCRIPTION..........................6
OPERATION............................6
REMOVAL.............................7
INSTALLATION..........................7
POWER OUTLET
DESCRIPTION..........................7
OPERATION............................7
DIAGNOSIS AND TESTING - POWER
OUTLET.............................7
REMOVAL.............................8
INSTALLATION..........................8
POWER DISTRIBUTION
DESCRIPTION
This group covers the various standard and
optional power distribution components used on this
model. The power distribution system for this vehicle
consists of the following components:
²Integrated Power Module (IPM)
²Front Control Module (FCM)
²Power Distribution Center (PDC)
²Power Outlets
²Cigar Lighter Outlets
²Relays
Refer to Wiring Diagrams for complete circuit sche-
matics.
The power distribution system also incorporates
various types of circuit control and protection fea-
tures, including:
²Automatic resetting circuit breakers
²Blade-type fuses
²Cartridge fuses
²Relays
Following are general descriptions of the major
components in the power distribution system. See the
owner's manual in the vehicle glove box for more
information on the features and use of all of the
power distribution system components.
OPERATION
The power distribution system for this vehicle is
designed to provide safe, reliable, and centralized dis-
tribution points for the electrical current required to
operate all of the many standard and optional facto-
ry-installed electrical and electronic powertrain,
chassis, safety, security, comfort and convenience sys-
tems. At the same time, the power distribution sys-
tem was designed to provide ready access to these
electrical distribution points for the vehicle techni-
cian to use when conducting diagnosis and repair of
faulty circuits. The power distribution system can
also prove useful for the sourcing of additional elec-
trical circuits that may be required to provide the
electrical current needed to operate many accessories
that the vehicle owner may choose to have installed
in the aftermarket.
DR8W-97 POWER DISTRIBUTION 8W - 97 - 1

ENGINE
TABLE OF CONTENTS
page page
ENGINE - 3.7L............................ 1
ENGINE - 4.7L........................... 88ENGINE - 5.7L.......................... 180
ENGINE 5.9L DIESEL..................... 230
ENGINE - 3.7L
TABLE OF CONTENTS
page page
ENGINE - 3.7L
DESCRIPTION..........................3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION............4
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE............4
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL..............6
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - LUBRICATION..............7
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE..............8
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE.......8
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS..........9
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS..........9
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION........10
REMOVAL.............................10
INSTALLATION.........................11
SPECIFICATIONS
SPECIFICATIONS - 3.7L ENGINE.........12
TORQUE............................16
SPECIAL TOOLS.......................17
AIR CLEANER ELEMENT
REMOVAL.............................21
INSTALLATION.........................21
CYLINDER HEAD - LEFT
DIAGNOSIS AND TESTING - CYLINDER HEAD
GASKET............................21
REMOVAL.............................22
INSTALLATION.........................24
CAMSHAFT(S)
DESCRIPTION.........................25
REMOVAL.............................25INSTALLATION.........................27
CYLINDER HEAD COVER(S)
DESCRIPTION.........................27
REMOVAL.............................28
INSTALLATION.........................28
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION.........................28
STANDARD PROCEDURE - REFACING......28
REMOVAL.............................29
INSTALLATION.........................30
ROCKER ARM
DESCRIPTION.........................31
REMOVAL.............................31
INSTALLATION.........................31
VALVE GUIDE SEALS
DESCRIPTION.........................32
VALVE SPRINGS
DESCRIPTION.........................32
REMOVAL.............................32
INSTALLATION.........................32
CYLINDER HEAD - RIGHT
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER.....................32
REMOVAL.............................33
INSTALLATION.........................34
CAMSHAFT(S)
DESCRIPTION.........................35
REMOVAL.............................35
INSTALLATION.........................36
CYLINDER HEAD COVER(S)
REMOVAL.............................37
INSTALLATION.........................37
ROCKER ARM
DESCRIPTION.........................37
REMOVAL.............................37
VALVE GUIDE SEALS
DESCRIPTION.........................38
VALVE SPRINGS
DESCRIPTION.........................38
DRENGINE 9 - 1

VALVE SPRING
DESCRIPTION SPECIFICATION
Metric Standard
Free Length
(Approx)
Intake 48.92 mm 1.9260 in.
Exhaust -
w/damper48.2 mm 1.897 in.
Spring Force
(Valve Closed)
Intake 361.0 - 390.0 N
@ 40.12 mm81.15 - 87.67
lbs. @ 1.5795
in.
Exhaust -
(without
damper)356-394N@
39.12 mm80.031 - 88.57
lbs. @ 1.54 in.
Spring Force
(Valve Open)
Intake 984.0 - 1040.0
N @ 27.12 mm221.2 - 233.8
lbs. @ 1.107 in.
Exhaust -
without damper974-956N@
28.12 mm196.48 - 214.91
lbs. @ 1.107 in.
Number of Coils
Intake 7.30
Exhaust 7.15
Wire Diameter
Intake 4.77 ý 3.80mm 0.1878 ý 0.1496
in.
Exhaust 4.66 ý 3.72mm 0.1843 ý .1464
in.
Installed Height
(Spring Seat to
Bottom of
Retainer)
Nominal
Intake 40.12 mm 1.579 in.
Exhaust -
w/damper40.12 mm 1.579 in.
CYLINDER HEAD
DESCRIPTION SPECIFICATION
Metric Standard
Gasket
Thickness
(Compressed)0.7 mm (0.0276 in.)
Valve Seat
Angle44.5É - 45.0É
Valve Seat
Runout (MAX)0.051 mm 0.002 in.
Valve Seat
Width
Intake 1.75 - 2.36 mm 0.0698 - 0.0928
in.
Exhaust 1.71 - 2.32 mm 0.0673 - 0.0911
in.
Guide Bore
Diameter (Std.)6.975 - 7.00
mm0.2747 - 0.2756
in.
Cylinder Head
Warpage
(Flatness)0.0508 mm 0.002 in.
OIL PUMP
DESCRIPTION SPECIFICATION
Metric Standard
Clearance Over
Rotors/End
Face (MAX)0.095 mm 0.0038 in.
Cover Out - of
-Flat (MAX)0.025 mm 0.001 in.
Inner and Outer
Rotor Thickness12.02 mm 0.4731 in.
Outer Rotor to
pocket
(Diametral)
clearance
(MAX).235 mm .0093 in.
Outer Rotor
Diameter (MIN)85.925 mm 0.400 in.
Tip Clearance
Between Rotors
(MAX)0.150 mm 0.006 in.
DRENGINE - 3.7L 9 - 15
ENGINE - 3.7L (Continued)

ENGINE - 4.7L
TABLE OF CONTENTS
page page
ENGINE - 4.7L
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE...........90
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL.............92
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE.............93
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE......93
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION...........94
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS.........94
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS.........94
REMOVAL.............................95
INSTALLATION.........................97
SPECIFICATIONS
SPECIFICATIONS - 4.7L ENGINE.........99
TORQUE...........................102
SPECIAL TOOLS
4.7L ENGINE........................103
AIR CLEANER ELEMENT
REMOVAL............................107
INSTALLATION........................107
CYLINDER HEAD
DESCRIPTION
DESCRIPTION - CYLINDER HEAD.......107
DESCRIPTION - VALVE GUIDES.........107
REMOVAL
REMOVAL - LEFT CYLINDER HEAD......108
REMOVAL - RIGHT CYLINDER HEAD.....110
CLEANING...........................111
INSPECTION..........................111
INSTALLATION
INSTALLATION - LEFT CYLINDER HEAD . . . 112
INSTALLATION - RIGHT CYLINDER HEAD . 113
CAMSHAFT(S) - LEFT
DESCRIPTION........................114
REMOVAL............................115
INSTALLATION........................116
CAMSHAFT(S) - RIGHT
DESCRIPTION........................119
REMOVAL............................119
INSTALLATION........................120
CYLINDER HEAD COVER(S)
DESCRIPTION........................122REMOVAL
REMOVAL - RIGHT SIDE...............122
REMOVAL - LEFT SIDE................122
CLEANING...........................123
INSTALLATION
INSTALLATION - RIGHT SIDE...........123
INSTALLATIONÐLEFT SIDE............123
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION........................123
REMOVAL............................124
INSTALLATION........................124
ROCKER ARM / ADJUSTER ASSEMBLY
DESCRIPTION........................125
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER.....................125
REMOVAL............................126
INSTALLATION........................126
VALVE SPRINGS
DESCRIPTION........................126
REMOVAL............................126
INSTALLATION........................127
VALVE STEM SEALS
DESCRIPTION........................127
ENGINE BLOCK
DESCRIPTION........................128
STANDARD PROCEDURE - CYLINDER BORE
HONING...........................128
CLEANING...........................128
INSPECTION.........................128
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING FITTING...............129
CORE PLUGS
REMOVAL............................131
INSTALLATION........................131
CRANKSHAFT
DESCRIPTION........................131
REMOVAL............................131
INSPECTION.........................132
INSTALLATION........................132
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDUREÐCRANKSHAFT
MAIN BEARING - FITTING..............134
INSPECTION.........................135
CRANKSHAFT OIL SEAL - FRONT
REMOVAL............................135
INSTALLATION........................136
9 - 88 ENGINE - 4.7LDR

CYLINDER HEAD
DESCRIPTION SPECIFICATION
Gasket Thickness
(Compressed)0.7 mm (0.0276 in.)
Valve Seat Angle 44.5É - 45.0É
Valve Seat Runout (MAX) 0.051 mm (0.002 in.)
Valve Seat Width
Intake 1.75 - 2.36 mm
(0.0698 - 0.0928 in.)
Exhaust 1.71 - 2.32 mm
(0.0673 - 0.0911 in.)
Guide Bore Diameter
(Std.)6.975 - 7.00 mm
(0.2747 - 0.2756 in.)
Cylinder Head Warpage
(Flatness)0.0508 mm (0.002 in.)
OIL PUMP
DESCRIPTION SPECIFICATION
Clearance Over
Rotors/End Face (MAX)0.095 mm (0.0038 in.)
Cover Out - of -Flat
(MAX)0.025 mm (0.001 in.)
Inner and Outer Rotor
Thickness12.02 mm (0.4731 in.)
Outer Rotor to pocket
(Diametral) clearance
(MAX).235 mm (.0093 in.)
Outer Rotor Diameter
(MIN)85.925 mm (0.400 in.)
Tip Clearance Between
Rotors (MAX)0.150 mm (0.006 in.)
OIL PRESSURE
SPECIFICATION SPECIFICATION
At Curb Idle Speed
(MIN)*48 kPa (7 psi)
@ 3000 rpm 240 - 725 kPa (35 - 105
psi)
* CAUTION: If pressure is zero at curb idle, DO
NOT run engine at 3000 rpm.
TORQUE
DESCRIPTION N´m Ft. In.
Lbs. Lbs.
Camshaft
Non - Oiled Sprocket Bolt 122 90 Ð
Bearing Cap Bolts 11 Ð 100
Timing Chain CoverÐBolts 58 43 Ð
Connecting Rod CapÐBolts 27 20 Ð
PLUS 90É TURN
Bed PlateÐBolts Refer to Procedure
Crankshaft DamperÐBolt 175 130 Ð
Cylinder HeadÐBolts
M11 Bolts 81 60 Ð
M8 Bolts 26 19 Ð
Cylinder Head CoverÐBolts 12 Ð 105
Exhaust ManifoldÐBolts 25 18 Ð
Exhaust Manifold Heat
ShieldÐNuts8Ð72
Then loosen 45É
FlexplateÐBolts 60 45 Ð
Engine Mount Bracket to
BlockÐBolts61 45 Ð
Rear Mount to
TransmissionÐBolts46 34 Ð
Generator MountingÐBolts
M10 Bolts 54 40 Ð
M8 Bolts 28 Ð 250
Intake ManifoldÐBolts 12 Ð 105
Refer to Procedure
for
Tightening Sequence
Oil PanÐBolts 15 Ð 130
Oil PanÐDrain Plug 34 25 Ð
Oil PumpÐBolts 28 Ð 250
Oil Pump CoverÐBolts 12 Ð 105
Oil Pickup TubeÐBolt and
Nut28 Ð 250
Oil Dipstick Tube to Engine
BlockÐBolt 15 Ð 130
Oil Fill TubeÐBolts 12 Ð 105
Timing Chain GuideÐBolts 28 Ð 250
Timing Chain Tensioner
ArmÐSpecial
9 - 102 ENGINE - 4.7LDR
ENGINE - 4.7L (Continued)

ENGINE - 5.7L
TABLE OF CONTENTS
page page
ENGINE - 5.7L
DESCRIPTION........................182
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION..........183
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE..........183
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL............185
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE............186
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE.....186
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - LUBRICATION............187
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL............188
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS........190
STANDARD PROCEDUREÐHYDROSTATIC
LOCK..............................190
REMOVAL............................190
INSTALLATION........................191
SPECIFICATIONS
5.7L ENGINE........................192
TORQUE...........................195
SPECIAL TOOLS
5.7L ENGINE........................196
AIR INTAKE SYSTEM
REMOVAL............................199
INSTALLATION........................199
CYLINDER HEAD
OPERATIONÐCYLINDER HEAD...........199
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET FAILURE....................199
REMOVAL............................200
CLEANING...........................200
INSPECTION.........................200
INSTALLATION........................200
CYLINDER HEAD COVER(S)
REMOVAL............................201
INSTALLATION........................201
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION
DESCRIPTION - VALVE GUIDES.........202
DESCRIPTION.......................202
STANDARD PROCEDURE - REFACING.....202
REMOVAL............................203INSTALLATION........................203
ROCKER ARM / ADJUSTER ASSY
REMOVAL............................203
INSTALLATION........................203
VALVE STEM SEALS
DESCRIPTION........................203
VALVE SPRINGS
REMOVAL............................204
INSTALLATION........................204
ENGINE BLOCK
CLEANING...........................205
INSPECTION.........................205
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVAL - CAMSHAFT CORE HOLE PLUG. 205
REMOVAL - CAMSHAFT...............205
INSPECTION.........................206
INSTALLATION
INSTALLATION - CAMSHAFT CORE HOLE
PLUG..............................206
INSTALLATION - CAMSHAFT............206
CRANKSHAFT
REMOVAL............................206
INSTALLATION........................207
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - CRANKSHAFT
MAIN BEARING - FITTING..............207
INSPECTION.........................208
CRANKSHAFT OIL SEAL - FRONT
REMOVAL............................208
INSTALLATION........................208
CRANKSHAFT OIL SEAL - REAR
DIAGNOSIS AND TESTING - REAR SEAL
AREA LEAKS........................209
REMOVAL............................209
INSTALLATION........................209
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL............................209
INSTALLATION........................210
FLEX PLATE
REMOVAL............................210
INSTALLATION........................210
HYDRAULIC TAPPETS
DIAGNOSIS AND TESTING - HYDRAULIC
TAPPETS...........................210
REMOVAL............................211
INSTALLATION........................211
PISTON & CONNECTING ROD
DESCRIPTION........................211
9 - 180 ENGINE - 5.7LDR

ENGINE 5.9L DIESEL
TABLE OF CONTENTS
page page
ENGINE 5.9L DIESEL
DESCRIPTION........................232
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - MECHANICAL............233
DIAGNOSIS AND TESTINGÐSMOKE
DIAGNOSIS CHARTS.................236
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION/LEAKAGE TESTS.......239
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS........239
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS........240
STANDARD PROCEDUREÐHYDROSTATIC
LOCK..............................240
REMOVAL
REMOVAL - ENGINE..................241
REMOVALÐCRANKCASE BREATHER....242
INSTALLATION
INSTALLATION - ENGINE..............242
INSTALLATIONÐCRANKCASE BREATHER . 243
SPECIFICATIONS
SPECIFICATIONS - 5.9L DIESEL.........244
TORQUE...........................245
SPECIAL TOOLS
5.9L DIESEL ENGINE.................246
ENGINE DATA PLATE
DESCRIPTION........................248
AIR CLEANER ELEMENT
REMOVAL............................248
INSTALLATION........................249
CYLINDER HEAD
DESCRIPTION........................249
REMOVAL............................249
CLEANING
CLEANINGÐCYLINDER HEAD..........251
CLEANINGÐCROSSHEADS............251
CLEANINGÐPUSHRODS..............252
INSPECTION
INSPECTION - CYLINDER HEAD.........252
INSPECTIONÐCROSSHEADS..........252
INSPECTIONÐPUSHRODS.............253
INSTALLATION........................253
CYLINDER HEAD COVER(S)
REMOVAL
REMOVALÐCYLINDER HEAD COVER....255
REMOVALÐROCKER HOUSING.........255
CLEANING...........................255INSPECTION.........................255
INSTALLATION
INSTALLATIONÐCYLINDER HEAD COVER . 255
INSTALLATION - ROCKER HOUSING.....255
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION........................256
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVES,
GUIDES AND SPRINGS................256
STANDARD PROCEDURE - VALVE LASH
ADJUSTMENT AND VERIFICATION.......259
REMOVAL - VALVE SPRINGS AND SEALS . . . 260
INSTALLATION........................261
ROCKER ARM / ADJUSTER ASSY
DESCRIPTION........................261
REMOVAL............................261
CLEANING...........................262
INSPECTION.........................262
INSTALLATION........................263
ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER
BLOCK REFACING...................264
STANDARD PROCEDURE - CYLINDER
BORE - DE-GLAZE...................264
STANDARD PROCEDUREÐCYLINDER
BORE REPAIR.......................265
STANDARD PROCEDUREÐCAM BORE
REPAIR ............................267
INSPECTION.........................267
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVALÐCAMSHAFT BEARINGS......268
REMOVAL - CAMSHAFT...............268
INSPECTION.........................270
INSTALLATION
INSTALLATION - CAMSHAFT BEARINGS . . 271
INSTALLATION - CAMSHAFT............271
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING AND CRANKSHAFT
JOURNAL CLEARANCE................272
CRANKSHAFT AND GEAR
DESCRIPTION........................273
REMOVAL - GEAR.....................273
INSTALLATION - GEAR..................273
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - MAIN BEARING
CLEARANCE........................274
9 - 230 ENGINE 5.9L DIESELDR

EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION
DESCRIPTION........................1
DESCRIPTION - 5.9L DIESEL.............3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - GAS ENGINE . . . 4
DIAGNOSIS AND TESTING - DIESEL
ENGINE..............................5
SPECIFICATIONS - TORQUE...............5
SPECIAL TOOLS........................6
CATALYTIC CONVERTER
DESCRIPTION - CATALYTIC CONVERTER.....6
OPERATION............................6
REMOVAL
REMOVAL............................6
REMOVAL............................6
INSPECTION...........................6
INSTALLATION
INSTALLATION........................6
INSTALLATION........................7
EXHAUST PIPE
REMOVAL - 3.7L/4.7L/5.7L.................7
INSPECTION...........................7
INSTALLATION - 3.7L/4.7L/5.7L..............7
EXHAUST PIPE
REMOVAL - DIESEL......................7
INSPECTION...........................8
INSTALLATION - DIESEL..................8
HEAT SHIELDS
DESCRIPTION..........................8
REMOVAL.............................8
INSTALLATION..........................8
MUFFLER
REMOVAL.............................9INSTALLATION..........................9
MUFFLER - 5.9L DIESEL
REMOVAL.............................10
INSTALLATION.........................10
TAILPIPE - 5.9L DIESEL
REMOVAL.............................10
INSPECTION..........................10
INSTALLATION.........................11
TAILPIPE
REMOVAL.............................11
INSPECTION..........................11
INSTALLATION.........................11
TURBOCHARGER SYSTEM
DIAGNOSIS AND TESTING -
TURBOCHARGER BOOST PRESSURE.....11
TURBOCHARGER
DESCRIPTION.........................12
OPERATION...........................13
REMOVAL.............................14
CLEANING............................15
INSPECTION..........................15
INSTALLATION.........................15
CHARGE AIR COOLER AND PLUMBING
DESCRIPTION.........................16
OPERATION...........................16
DIAGNOSIS AND TESTING - CHARGE AIR
COOLER SYSTEM - LEAKS..............16
REMOVAL.............................17
CLEANING............................17
INSPECTION..........................17
INSTALLATION.........................17
EXHAUST SYSTEM
DESCRIPTION
DESCRIPTION
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem floor pan exhaust heat shields. Light overspray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.The federal gasoline engine exhaust system con-
sists of engine exhaust manifolds, exhaust pipes, cat-
alytic converter(s), extension pipe (if needed),
exhaust heat shields, muffler and exhaust tailpipe
(Fig. 1), (Fig. 2), (Fig. 3)
The California emission vehicles exhaust system
also contains the above components as well as mini
catalytic converters added to the exhaust pipe.
The exhaust system must be properly aligned to
prevent stress, leakage and body contact. Minimum
clearance between any exhaust component and the
body or frame is 25.4 mm (1.0 in.). If the system con-
tacts any body panel, it may amplify objectionable
noises from the engine or body.
DREXHAUST SYSTEM 11 - 1