Camshaft DODGE RAM 1500 1998 2.G Workshop Manual

(15) Remove timing chain(Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(16) Remove camshaft tensioner/thrust plate
assembly.
NOTE: Identify tappets to ensure installation in orig-
inal location.
(17) Remove the retainer assembly and tappets.
(18) Install a long bolt into front of camshaft to aid
in removal of the camshaft. Remove camshaft, being
careful not to damage cam bearings with the cam
lobes.
INSPECTION
(1) The cam bearings are not serviceable. Do not
attempt to replace cam bearings for any reason.
INSTALLATION
INSTALLATION - CAMSHAFT CORE HOLE PLUG
CAUTION: The new core hole plug must be installed
to the proper depth or camshaft damage could
develope. The plug must be installed squarely in
the bore.
(1) Install a new core hole plug at the rear of cam-
shaft, using special tool # 9048. Clean plug and apply
mopartlock and seal adhesive to the edge of the
plug, before installing. The plug must be installed to
a depth of+/-0.25mm from the end of the machined
bevel, that is the end of the bevel that is closest to
the cam bearing.
INSTALLATION - CAMSHAFT
(1) Lubricate camshaft lobes and camshaft bearing
journals and insert the camshaft
(2) Install camshaft Tensioner plate assembly.
Tighten bolts to 28 N´m (250 in. lbs.) torque.
(3) Install timing chain and sprockets(Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION) .
(4) Measure camshaft end play(Refer to 9 -
ENGINE - SPECIFICATIONS). If not within limits
install a new thrust plate.
(5) Install the oil pump(Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(6) Install the oil pick up tube.
(7) Each tappet reused must be installed in the
same position from which it was removed.When
camshaft is replaced, all of the tappets must be
replaced.(8) Install the tappets and retainer assembly(Refer
to 9 - ENGINE/ENGINE BLOCK/HYDRAULIC LIFT-
ERS (CAM IN BLOCK) - INSTALLATION).
(9) Install both left and right cylinder heads(Refer
to 9 - ENGINE/CYLINDER HEAD - INSTALLA-
TION) .
(10) Install pushrods
(11) Install rocker arms(Refer to 9 - ENGINE/CYL-
INDER HEAD/ROCKER ARM / ADJUSTER ASSY -
INSTALLATION).
(12) Install timing case cover(Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(13) Install the oil pan(Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
(14) Install cylinder head covers(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(15) Install intake manifold(Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSTALLA-
TION).
(16) Install the A/C compressor, and set aside
(17) Install the generator.
(18) Install the accessory drive belt.
(19) Install the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION).
(20) Install the air cleaner assembly.
(21) Install the battery negative cable.
(22) Refill coolant.
(23) Refill engine oil.
(24) Start engine and check for leaks.
CRANKSHAFT
REMOVAL
(1) Remove the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(2) Remove the oil pan(Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(3) Remove the oil pump pickup.
(4) Remove the windage tray/oil pan gasket.
(5) Remove the timing chain cover(Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(6) Remove the oil pump(Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - REMOVAL).
(7) Remove the timing drive(Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(8) Identify rod bearing caps before removal.
Remove rod bearing caps with bearings.
(9) Identify main bearing caps before removal.
Remove main bearing caps and bearings one at a
time.
9 - 206 ENGINE - 5.7LDR
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

CRANKSHAFT OIL SEAL -
REAR
DIAGNOSIS AND TESTING - REAR SEAL AREA
LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak:
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, camshaft bore
cup plugs, oil galley pipe plugs, oil filter runoff,
and main bearing cap to cylinder block mating sur-
faces. See Engine, for proper repair procedures of
these items.
(4) If no leaks are detected, pressurized the crank-
case as outlined in the section, Inspection (Engine oil
Leaks in general)
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks or
scratches. The crankshaft seal flange is specially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled. (Refer to 9 - ENGINE - DIAGNOSIS AND
TESTING), under the Oil Leak row, for components
inspections on possible causes and corrections.
(7) After the oil leak root cause and appropriate
corrective action have been identified, (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - REMOVAL).
REMOVAL
NOTE: This procedure can be performed in vehicle.
(1) If being preformed in vehicle, remove the
transmission.
(2) Remove the flexplate (Refer to 9 - ENGINE/
ENGINE BLOCK/FLEX PLATE - REMOVAL).
NOTE: The crankshaft oil seal CAN NOT be reused
after removal.
NOTE: The crankshaft rear oil seal remover Special
Tool 8506 must be installed deeply into the seal.
Continue to tighten the removal tool into the seal
until the tool can not be turned farther. Failure to
install tool correctly the first time will cause tool to
pull free of seal without removing seal from engine.
(3) Using Special Tool 8506, remove the crankshaft
rear oil seal.
INSTALLATION
CAUTION: The rear seal must be installed dry for
proper operation. Do not lubricate the seal lip or
outer edge.
(1) Position the plastic seal guide onto the crank-
shaft rear face. Then position the crankshaft rear oil
seal onto the guide.
(2) Using Special Tools 8349 Crankshaft Rear Oil
Seal Installer and C-4171 Driver Handle, with a
hammer, tap the seal into place. Continue to tap on
the driver handle until the seal installer seats
against the cylinder block crankshaft bore.
(3) Install the flexplate.
(4) Install the transmission.
CRANKSHAFT REAR OIL SEAL
RETAINER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the transmission.
(3) Remove the drive plate / flywheel.
(4) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(5) Remove the rear oil seal retainer mounting
bolts.
(6) Carefully remove the retainer from the engine
block.
DRENGINE - 5.7L 9 - 209

REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Remove the air cleaner(Refer to 9 - ENGINE/
AIR INTAKE SYSTEM - REMOVAL).
(3) Remove intake manifold(Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - REMOVAL).
(4) Remove cylinder head cover(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(5) Remove rocker arm assembly and push rod-
s(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARM / ADJUSTER ASSY - REMOVAL). Identify
push rods to ensure installation in original location.
(6) Remove the cylinder head(Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(7) Remove bolt from tappet guide holder.
(8) Remove tappet guide holder.
(9) Pull tappet out of bore with a twisting motion.
If all tappets are to be removed and reused, identify
tappets to ensure installation in original location.
(10) Check camshaft lobes for abnormal wear.
INSTALLATION
(1) Lubricate tappets.
(2) Install tappets in their original positions.
(3)
Install tappet guide holder. Install the tappet
guide holder bolt and tighten to 12 N´m (106 in. lbs.)
torque.
(4) Install cylinder head(Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
(5) Install pushrods and rocker arm assembly(Re-
fer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARM / ADJUSTER ASSY - INSTALLATION).
(6) Install cylinder head cover(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(7)
Install intake manifold(Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSTALLATION).
(8) Install the air cleaner(Refer to 9 - ENGINE/
AIR INTAKE SYSTEM - INSTALLATION).
(9) Connect the negative cable to the battery.
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.
(10) Road test vehicle and check for leaks.
PISTON & CONNECTING ROD
DESCRIPTION
CAUTION: Do not use a metal stamp to mark con-
necting rods as damage may result, instead use ink
or a scratch awl.The pistons are made of a high strength aluminum
alloy. Piston skirts are coated with a solid lubricant
(Molykote) to reduce friction and provide scuff resis-
tance. The piston top ring groove and land is anod-
ized. The connecting rods are made of forged
powdered metal, with a ªfractured capº design. A
pressed fit piston pin is used to attach the piston and
connecting rod.
STANDARD PROCEDUREÐPISTON FITTING
(1) To correctly select the proper size piston, a cyl-
inder bore gauge, capable of reading in 0.003 mm (
.0001 in.) INCREMENTS is required. If a bore gauge
is not available, do not use an inside micrometer.
(2) Measure the inside diameter of the cylinder
bore at a point 38.0 mm (1.5 inches) below top of
bore. Start perpendicular (across or at 90 degrees) to
the axis of the crankshaft at point A and then take
an additional bore reading 90 degrees to that at point
B (Fig. 11).
(3) The coated pistons will be serviced with the
piston pin and connecting rod pre-assembled. The
piston-rod assembly is specific for the left cylinder
bank ( odd numbered) and the right cylinder bank (
even numbered) and must not be interchanged.
(4) The coating material is applied to the piston
after the final piston machining process. Measuring
the outside diameter of a coated piston will not pro-
vide accurate results (Fig. 10). Therefore measuring
the inside diameter of the cylinder bore with a dial
Bore Gauge isMANDATORY. To correctly select the
proper size piston, a cylinder bore gauge capable of
reading in 0.003 mm (.0001 in.) increments is
required.
Fig. 10 MOLY COATED PISTON
1 - MOLY COATED
2 - MOLY COATED
DRENGINE - 5.7L 9 - 211
HYDRAULIC TAPPETS (Continued)

If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak:
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, distributor seal,
camshaft bore cup plugs oil galley pipe plugs, oil
filter runoff, and main bearing cap to cylinder
block mating surfaces.
(4) If no leaks are detected, pressurize the crank-
case as outlined in the, Inspection (Engine oil Leaks
in general)
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled.
OIL
STANDARD PROCEDURE - ENGINE OIL
SERVICE
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certi-
fied. MOPARtprovides engine oils that conform to
this service grade.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. Use only engine oils with multi-
ple viscosities such as 5W-30 in the 5.7L engines.
These are specified with a dual SAE viscosity grade
which indicates the cold-to-hot temperature viscosity
range. Select an engine oil that is best suited to your
particular temperature range and variation.
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for
gasoline engines. The designation of ENERGY CON-
SERVING is located on the label of an engine oil con-
tainer.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the label
of engine oil plastic bottles and the top of engine oil
cans (Fig. 28).
OIL LEVEL INDICATOR (DIPSTICK)
The engine oil level indicator is located at the left
hand of the engine on the 5.7L engines.
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil,
pressure loss or oil foaming can result.
Inspect engine oil level approximately every 800
kilometers (500 miles). Unless the engine has exhib-
ited loss of oil pressure, run the engine for about ten
Fig. 28 API SYMBOL
9 - 222 ENGINE - 5.7LDR
LUBRICATION (Continued)

TIMING/CHAIN AND
SPROCKETS
REMOVAL
(1) Disconnect battery negative cable.
(2) Drain cooling system.
(3) Remove Timing Chain Cover.
CAUTION: The camshaft pin and the slot in the cam
sprocket must be clocked at 12:00. The crankshaft
keyway must be clocked at 2:00. The crankshaft
sprocket must be installed so that the dots and or
paint marking is at 6:00.
(4) Re-install the vibration damper bolt finger
tight. Using a suitable socket and breaker bar, rotate
the crankshaft to align timing chain sprockets and
keyways as shown (Fig. 33).
(5) Retract tensioner shoe until hole in shoe lines
up with hole in bracket. Slide a suitable pin into the
holes.
(6) Remove camshaft sprocket attaching bolt and
remove timing chain with crankshaft and camshaft
sprockets.
(7) If tensioner assembly is to be replaced, remove
the tensioner to block bolts and remove tensioner
assembly.
INSTALLATION
(1) If tensioner assembly is being replaced, install
tensioner and mounting bolts. Torque bolts to 28 N´m
(250 in. lbs.).
(2) Retract tensioner if required.
CAUTION: The camshaft pin and the slot in the cam
sprocket must be clocked at 12:00. The crankshaft
keyway must be clocked at 2:00. The crankshaft
sprocket must be installed so that the dots and or
paint marking is at 6:00.
(3) 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. 34).
CAUTION: The timing chain must be installed with
the single plated link aligned with the dot and or
paint marking on the camshaft sprocket. The crank-
shaft sprocket is aligned with the dot and or paint
marking on the sprocket between two plated timing
chain links.
(4) Place timing chain around both sprockets (Fig.
34).
(5) Lift sprockets and chain (keep sprockets tight
against the chain in position as shown).
(6) Slide both sprockets evenly over their respec-
tive shafts and check alignment of timing marks.
Fig. 33 5.7L TIMING MARK ALIGNMENT
1 - Chain Tensioner
2 - Camshaft Sprocket
3 - Crankshaft Sprocket
Fig. 34 5.7L TIMING MARK ALIGNMENT
1 - Chain Tensioner
2 - Camshaft Sprocket
3 - Crankshaft Sprocket
9 - 228 ENGINE - 5.7LDR

(7) Install the camshaft bolt. Tighten the bolt to
122 N´m (90 ft. lbs.) torque.
(8)Remove tensioner pin.Again, verify align-
ment of timing marks.
(9) Install the oil pump(Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(10) Install the oil pan and pick up(Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
(11) Install the timing chain cover(Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(12) Fill cooling system(Refer to 7 - COOLING -
STANDARD PROCEDURE).
(13) Connect battery negative cable.
(14) Start engine and check for oil and coolant
leaks.TIMING CHAIN/TENSIONER
DESCRIPTION
The timing chain tensioner is a stamped steel con-
stant tension mechanical design. It is mounted to the
front of the engine, behind the timing chain drive.
OPERATION
The timing chain tension is maintained by routing
the timing chain through the tensioner assembly. A
nylon covered spring steel arm presses on the timing
chain maintaining the correct chain tension.
DRENGINE - 5.7L 9 - 229
TIMING/CHAIN AND SPROCKETS (Continued)

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

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

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

After removing the boring bar, use a honing stone
to chamfer the corner of the repair sleeve(s).
SLEEVE MACHINING DIMENSIONS CHART
ITEM MEASUREMENT
SLEEVE PROTRUSION MIN. - FLUSH WITH
BLOCK
MAX. - 0.050 mm
(0.0019 in.)
SLEEVE DIAMETER 101.956 mm (4.014 in.)
SLEEVE CHAMFER APPROX. 1.25 mm
(0.049 in.) by 15É
A correctly honed surface will have a crosshatch
appearance with the lines at 15É to 25É angles with
the top of the cylinder block. For the rough hone, use
80 grit honing stones. To finish hone, use 280 grit
honing stones.
Finished bore inside dimension is 102.020  0.020
mm (4.0165  0.0008 inch).
A maximum of 1.2 micrometer (48 microinch) sur-
face finish must be obtained.
After finish honing is complete, immediately clean
the cylinder bores with a strong solution of laundry
detergent and hot water.
After rinsing, blow the block dry with compressed
air.
Wipe the bore with a white, lint-free, lightly oiled
cloth. Make sure there is no grit residue present.
Apply a rust-preventing compound if the block will
not be used immediately.
A standard diameter piston and a piston ring set
must be used with a sleeved cylinder bore.
STANDARD PROCEDUREÐCAM BORE REPAIR
For standard bushings, not oversized, maximum
front and rear cam bushing bore diameter is 59.248
mm. (2.3326 in.). DO NOT bore the intermediate cam
bore to the front cam bore oversize dimensions. Max-
imum front and rear camshaft bushing installed
diameter is 54.147 mm. (2.1318 in.). Minimum
installed diameter is 54.083 mm. (2.1293 in.). Maxi-
mum intermediate camshaft bore diameter is 54.164
mm. (2.1324 in.).
A surface finish of 2.3 micrometers (92 microinch)
must be maintained. Not more than 20% of an area
of any one bore may be 3.2 micrometers (126 micro-
inch).
Camshaft bores can be repaired individually. It is
not necessary to repair undamaged cam bores in
order to repair individually damaged cam bores. The
standard front bushing cannot be used to repair
intermediate bores.Install all cam bushings flush or below the front
and rear cam bore surface. The front camshaft bush-
ing should be installed flush with front face of block.
The rear camshaft bushing should be installed flush
with rear face of block. The oil hole must align to
allow a 3.2 mm (0.125 inch) rod to pass through
freely (Fig. 52).
INSPECTION
Measure the combustion deck face using a straight
edge and a feeler gauge (Fig. 53). Cylinder block flat-
ness: End-to-end 0.076 mm ( .003 in.). Maximum
variation side-to-side 0.051 mm (.002 in.).
Inspect for any localized dips or imperfections.
If the surface exceeds the limit, (Refer to 9 -
ENGINE/ENGINE BLOCK - STANDARD PROCE-
DURE).
Fig. 52 Oil Hole Alignment
1 - CAMSHAFT BUSHING
Fig. 53 Combustion Deck Face Measurement
1 - STRAIGHT EDGE
2 - FEELER GAUGE
DRENGINE 5.9L DIESEL 9 - 267
ENGINE BLOCK (Continued)