Engine Installation DODGE RAM 1500 1998 2.G Workshop Manual

material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARtATF RTV
MopartATF RTV is a specifically designed black
silicone rubber RTV that retains adhesion and seal-
ing properties to seal components exposed to auto-
matic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKER
MopartGasket Maker is an anaerobic type gasket
material. The material cures in the absence of air
when squeezed between two metallic surfaces. It will
not cure if left in the uncovered tube. The anaerobic
material is for use between two machined surfaces.
Do not use on flexible metal flanges.
MOPARtGASKET SEALANT
MopartGasket Sealant is a slow drying, perma-
nently soft sealer. This material is recommended for
sealing threaded fittings and gaskets against leakage
of oil and coolant. Can be used on threaded and
machined parts under all temperatures. This mate-
rial is used on engines with multi-layer steel (MLS)
cylinder head gaskets. This material also will pre-
vent corrosion. MopartGasket Sealant is available in
a 13 oz. aerosol can or 4oz./16 oz. can w/applicator.
FORM-IN-PLACE GASKET AND SEALER
APPLICATION
Assembling parts using a form-in-place gasket
requires care but it's easier than using precut gas-
kets.
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.MopartGasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
STANDARD PROCEDURE - REPAIR DAMAGED
OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repaired. Essen-
tially, this repair consists of:
²Drilling out worn or damaged threads.
²Tapping the hole with a special Heli-Coil Tap, or
equivalent.
²Installing an insert into the tapped hole to bring
the hole back to its original thread size.
STANDARD PROCEDUREÐHYDROSTATIC
LOCK
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock
(regardless of what caused the problem), follow the
steps below.
(1) Disconnect the negative cable(s) from the bat-
tery.
(2) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(3) Place a shop towel around the fuel injectors to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the fuel injectors (Refer
to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL
INJECTOR - REMOVAL).
(4) With all injectors removed, rotate the crank-
shaft using the crankshaft barring tool (PN 7471±B).
(5) Identify the fluid in the cylinders (coolant, fuel,
oil, etc.).
(6) Be sure all fluid has been removed from the
cylinders.
(7) Repair engine or components as necessary to
prevent this problem from occurring again.
(8) Squirt a small amount of engine oil into the
cylinders to lubricate the walls. This will prevent
damage on restart.
(9) Install fuel injectors (Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/FUEL INJECTOR -
INSTALLATION).
9 - 240 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

(10) Drain engine oil. Remove and discard the oil
filter (Refer to 9 - ENGINE/LUBRICATION/OIL FIL-
TER - REMOVAL).
(11) Install the drain plug. Tighten the plug to 50
N´m (37 ft. lbs.) torque.
(12) Install a new oil filter (Refer to 9 - ENGINE/
LUBRICATION/OIL FILTER - INSTALLATION).
(13) Fill engine crankcase with the specified
amount and grade of oil (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES - SPECIFICA-
TIONS).
(14) Connect the negative cable(s) to the battery.
(15) Start the engine and check for any leaks.
REMOVAL
REMOVAL - ENGINE
(1) Disconnect both battery negative cables.
(2) Disconnect engine grid heater harness at grid
heater relays.
(3) Disconnect electrical connections from rear of
alternator.
(4) Recover A/C refrigerant. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE).
(5) Raise vehicle on a hoist.
(6) Drain engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(7) Remove engine oil drain plug and drain engine
oil.
(8) Reinstall drain plug. Tighten to 50N´m (37 ft.
lbs.) torque.
(9) Lower the vehicle.
(10) Remove fan/drive assembly. Refer to Section 7
± Fan/Drive Removal
(11) Remove radiator upper hose.
(12) Remove upper fan shroud mounting bolts.
(13) Disconnect the coolant recovery bottle hose
from the radiator fill neck and remove bottle.
(14) Using a 36mm wrench, remove viscous fan/
drive assembly. (Refer to 7 - COOLING/ENGINE/RA-
DIATOR FAN - REMOVAL).
(15) Remove cooling fan and shroud together.
(16) Disconnect heater core supply and return
hoses from the cylinder head fitting and coolant pipe.
(17) Raise vehicle on a hoist.
(18) Remove transmission and transfer case (if
equipped).
(19) Disconnect exhaust pipe from turbocharger
extension pipe.
(20) Disconnect engine harness to vehicle harness
connectors.
(21) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).(22) Remove flywheel/flexplate.
(23) Remove transmission adapter
(24) Disconnect A/C suction/discharge hose from
the rear of the A/C compressor.
(25) Lower vehicle.
(26) Disconnect lower radiator hose from radiator
outlet.
(27) Automatic transmission models:
(28) Disconnect transmission oil cooler lines from
in front of radiator using special tool #6931
(29) Remove radiator. (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(30) If A/C equipped, disconnect A/C condenser
refrigerant lines.
(31) Disconnect charge air cooler piping.
(32) Remove charge air cooler mounting bolts.
(33) Remove charge air cooler (and A/C condenser
if equipped) from vehicle.
(34) Remove damper and speed indicator ring from
front of engine.
(35) Disconnect engine block heater connector.
(36) Disconnect A/C compressor and pressure sen-
sor electrical connectors.
(37) Remove the passenger battery ground cable
from the engine block. Remove the driver side bat-
tery ground cable from the engine block.
(38) Remove power steering pump from engine by
removing 3 bolts.
(39) Remove accelerator linkage cover.
(40) Disconnect cables from on-engine APPS.
(41) Disconnect the ECM power connector.
(42) Disconnect the ECM ground wire from the
hydroform screw.
(43) Disconnect the fuel supply and return hoses.
(44) Remove the cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(45) Disconnect the 3 injector harness connectors
at the rocker housing. Disconnect the wire harnesses
from the injectors.
(46) Remove the rear engine lift bracket.
(47) Remove cylinder #4, #5, and #6 intake and
exhaust rocker arms, pedestals, and push tubes. Note
the original location for re-assembly.
(48) Loosen #6 fuel line shield bolts and rotate
shield out of the way.
(49) Remove cylinder #5 and #6 high pressure fuel
lines. Remove the fuel connector tube nut and fuel
connector tube. Remove cylinder #5 and #6 fuel injec-
tor.
(50) Remove rocker housing.
DRENGINE 5.9L DIESEL 9 - 241
ENGINE 5.9L DIESEL (Continued)

(51) Remove two cylinder head bolts according to
the diagram below and install Tool # 9009. Torque
bolts to 105N´m (77ft. lbs.) (Fig. 3).
(52) Loosen but do not remove engine mount
through bolts and nuts.
(53) Disconnect hood support struts and position
hood out of the way.
(54) Attach a chain with two hooks to the engine
lift brackets.
(55) While keeping engine level, lift straight up
out of the mounts.
(56) Rotate nose of engine upward and pull out of
chassis.
REMOVALÐCRANKCASE BREATHER
(1) Remove the oil fill cap.
(2) Remove the breather cover bolts (Fig. 4).
(3) Remove breather cover.
(4) Disconnect breather tube and lube oil drain
tube from breather.
(5) Remove breather mounting bolts.
(6) Remove breather from cylinder head cover.
INSTALLATION
INSTALLATION - ENGINE
(1) Remove cylinder head bolts according to the
diagram below. Install special Tool 9009. Torque bolts
to 105N´m (77ft. lbs.)
(2) Lower engine into the engine compartment and
install the engine the engine mount through bolts
and nuts.
(3) Tighten the mount through bolts and nuts to
88 N-m (65 ft-lbs) torque.
(4) Remove the engine lifting device (Tool 9009).
(5) Check cylinder head capscrew length and
install into cylinder head.
(6) Torque in 4 steps to:
²Step 1ÐTighten to 70 N´m (52 ft. lbs.) torque.
²Step 2ÐBack off 360É.
²Step 3ÐTighten to 105 N´m (77 ft. lbs.) torque.
²Step 4ÐRotate 90É.
(7) Install rocker housing. Torque to 24 N-m (18 ft-
lbs). Refer to (Refer to 9 - ENGINE/CYLINDER
HEAD/CYLINDER HEAD COVER(S) - INSTALLA-
TION).
Fig. 3 ENGINE LIFT BRACKET
1 - Head bolt
2 - Engine Lift Bracket
3 - Head Bolt
Fig. 4 Crankcase Breather Vapor Canister
1 - BREATHER COVER BOLT
2 - BREATHER COVER
3 - BREATHER TUBE
4 - ROCKER COVER
5 - BREATHER TUBE MOUNTING BRACKET
6 - LUBE OIL DRAIN TUBE
7 - O-RING
8 - BREATHER
9- BREATHER MOUNTING BOLT
9 - 242 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

(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)

SPECIAL TOOLS
5.9L DIESEL ENGINE
Universal Driver Handle - C4171
Crankshaft Barring Tool - 7471 - B
Crankshaft Front Oil Seal Installer - 8281
Valve Spring Compressor - 8319A
Test Plug - 8442
Adapter - 8462
Engine Support Fixture - 8534
TAPPET INSTALLATION TOOL - 8502
STEEL BRACKET - 8534-A
9 - 246 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

ENGINE DATA PLATE
DESCRIPTION
The engine data plate contains specific information
that is helpful to servicing and obtaining parts for
the engine. The data plate can be found affixed to the
breather cover on the left side of the engine. Informa-
tion that can be found on the data plate includes:
²Date of Engine Manufacture
²Engine Serial Number
²Control Parts List (CPL)
²Engine Rated Horsepower
²Engine Firing Order
²Engine Displacement
²Valve Lash Reset Specifications
If the engine data plate is missing or not legible,
the engine serial number is used for engine identifi-
cation. The engine serial number is stamped on the
right side of the block, on top of the oil cooler cavity
(Fig. 5).
AIR CLEANER ELEMENT
REMOVAL
Testing Air Cleaner Element using Filter MinderŸ
Do not attempt to unnecessarily remove top
of air cleaner housing for air cleaner element
inspection on diesel engines.
The air cleaner (filter) housing is equipped with an
air Filter MinderŸ gauge (Fig. 6). This air flow
restriction gauge will determine when air cleaner ele-
ment is restricted and should be replaced.
The Filter MinderŸ consists of a diaphragm and
calibrated spring sealed inside of a plastic housing
(Fig. 7). A yellow colored disc attached to diaphragm
moves along a graduated scale on side of Filter
Minder. After the engine has been shut off, a ratch-
eting device located within Filter Minder will hold
yellow disc at highest restriction that air cleaner ele-
ment has experienced. A drop in air pressure due toan air cleaner element restriction moves diaphragm
and yellow disc will indicate size of air drop.
CAUTION: Certain engine degreasers or cleaners
may discolor or damage plastic housing of Filter
Minder. Cover and tape Filter Minder if any engine
degreasers or cleaners are to be used.
To test, turn engine off. If yellow disc (Fig. 7) has
reached red colored zone on graduated scale, air
cleaner element should be replaced. Refer to Removal
/ Installation.
Resetting Filter Minder:After air cleaner (filter)
element has been replaced, press rubber button on
top of Filter Minder (Fig. 7). This will allow yellow
colored disc to reset. After button has been pressed,
yellow disc should spring back to UP position.
If Filter Minder gauge has reached red colored
zone, and after an examination of air cleaner (filter)
element, element appears to be clean, high reading
may be due to a temporary condition such as snow
build-up at air intake. Temporary high restrictions
may also occur if air cleaner (filter) element has got-
ten wet such as during a heavy rain or snow. If this
occurs, allow element to dry out during normal
engine operation. Reset rubber button on top of Filter
Minder and retest after element has dried.
Fig. 5 Engine Serial Number Location
Fig. 6 5.9L DIESEL AIR CLEANER - FILTER
MINDERŸ
1 - CLIPS
2 - FILTER COVER
3 - FILTER MINDERŸ
4 - INLET AIR TEMPERATURE/ PRESSURE SENSOR
5 - FILTER HOUSING
9 - 248 ENGINE 5.9L DIESELDR

Filter Removal
(1) The housing cover is equipped with spring clips
(Fig. 6) and is hinged with plastic tabs. Unlatch clips
from top of air cleaner housing and tilt housing cover
up for cover removal.
(2) Remove air cleaner element from air cleaner
housing.
INSTALLATION
(1) Before installing new air cleaner element (fil-
ter), clean inside of air cleaner housing.
(2) Position air cleaner cover to tabs on front of air
cleaner housing. Latch spring clips to seal cover to
housing.
CYLINDER HEAD
DESCRIPTION
The cylinder head is constructed of cast iron and is
a one piece cross flow design with four valves per cyl-
inder. The arrangement of two intake and two
exhaust valves per cylinder allows for a centrally
located injector. The cylinder head also includes an
integral intake manifold, an integral thermostat
housing, and a longitudal fuel return rifle, which
exits at the rear of the head. The 24 valve design
also includes integrally cast valve guides and hard-
ened intake and exhaust valve seat inserts.
REMOVAL
(1) Disconnect battery negative cables.
(2) Raise vehicle on hoist.
(3) Drain engine coolant.
(4) Disconnect exhaust pipe from turbocharger
elbow.
(5) Disconnect turbocharger oil drain tube at rub-
ber hose connection. Cap off open ports to prevent
intrusion of dirt or foreign material.
(6) Lower vehicle.
(7) Disconnect air inlet temperature/pressure sen-
sor.
(8) Remove air cleaner housing and snorkel from
the vehicle. Cap off turbocharger air inlet to prevent
intrusion of dirt or foreign material.
(9) Disconnect cab heater core supply and return
hoses from the cylinder head and heater pipe.
(10) Disconnect turbocharger oil supply line at the
turbocharger end. Cap off open ports to prevent
intrusion of dirt or foreign material.
(11) Remove exhaust manifold-to-cylinder head
bolts, spacers, heat shield, retention straps, and cab
heater plumbing. Remove exhaust manifold and tur-
bocharger from the vehicle as an assembly.
(12) Remove cooling fan assembly.
(13) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(14) Remove cooling fan support from cylinder
block.
(15) Remove upper generator bolt, loosen lower
generator bolt, and rotate generator away from cylin-
der head.
(16) Disconnect radiator upper hose from the ther-
mostat housing.
(17) Disconnect the Intake Air Temperature/Mani-
fold Air Pressure, and Coolant Temperature sensor
connectors.
(18) Remove the engine harness to cylinder head
attaching bolts and P-clips at front of head.
(19) Remove the throttle linkage cover (Fig. 8).
(20) For automatic equipped vehicles only, remove
the six (6) accelerator pedal position sensor assem-
bly-to-cylinder head bracket bolts (Fig. 9) and secure
the entire assembly out of the way. Disconnect the
APPS connector (Fig. 10).It is not necessary to
disconnect the cables from the throttle control
assembly.
(21) Remove the intake air grid heater wires from
the grid heater.
(22) Remove engine oil level indicator tube attach-
ing bolt at fuel filter housing bracket and inlet air
connection..
(23) Remove the charge air cooler-to-air inlet hous-
ing pipe.
Fig. 7 FILTER MINDERŸ - 5.9L DIESEL
1 - PRESS BUTTON TO RESET
2 - YELLOW DISC
3 - RED ZONE
4 - TO AIR FILTER HOUSING
5 - FILTER MINDER
DRENGINE 5.9L DIESEL 9 - 249
AIR CLEANER ELEMENT (Continued)

INSPECTIONÐPUSHRODS
Inspect the push rod ball and socket for signs of
scoring. Check for cracks where the ball and the
socket are pressed into the tube (Fig. 16).
Roll the push rod on a flat work surface with the
socket end hanging off the edge (Fig. 17). Replace
any push rod that appears to be bent.
INSTALLATION
WARNING: THE OUTSIDE EDGE OF THE HEAD
GASKET IS VERY SHARP. WHEN HANDLING THE
NEW HEAD GASKET, USE CARE NOT TO INJURE
YOURSELF.
(1) Install a new gasket with the part number side
up, and locate the gasket over the dowel sleeves.
(2) Using an engine lifting crane, lower the cylin-
der head onto the engine.
(3) Lightly lubricate head bolts with engine oil and
install. Using the sequence shown in (Fig. 18),
tighten bolts in the following steps:
(a) Torque bolts to 70 N´m (52 ft. lbs.)(b) Back off 360 degrees in sequence
(c) Torque bolts to 105 N´m (77 ft. lbs.)
(d) Re-check all bolts to 105 N´m (77 ft. lbs.)
(e) Tighten all bolts an additional
1¤4turn (90É)
(4) Install push rods into their original locations
(Fig. 19).Verify that they are seated in the tap-
pets.
(5) Lubricate valve stem tips and install the cross-
heads in their original locations.
(6) Lubricate the rocker arms and pedestals and
install them in their original locations (Fig. 20).
Install the bolts and torque them to 36 N´m (27 ft.
lbs.).
(7) Verify that the valve lash settings are main-
tained (Refer to 9 - ENGINE/CYLINDER HEAD/IN-
TAKE/EXHAUST VALVES & SEATS - STANDARD
PROCEDURE).
(8) Inspect rocker housing gasket for cuts and
proper installation into groove. Replace if damaged.
Fig. 16 Inspecting Push Rod for Cracks
Fig. 17 Inspecting Push Rod for Flatness
Fig. 18 Cylinder Head Bolt Torque Sequence
Fig. 19 Push Rod Installation
DRENGINE 5.9L DIESEL 9 - 253
CYLINDER HEAD (Continued)

(9) Install rocker housing and bolts. Tighten to 24
Nm (18 lb. ft.).
(10) Install fuel injector(Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/FUEL INJECTOR -
INSTALLATION).
(11) Install injector harness nuts. Tighten to 1.25
Nm (11 lb. in.).
(12) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(13) Install wire harness P-clip to cylinder head
behind filter housing 24 N´m (18 ft. lbs.).
(14) Connect the IAT/MAP sensor connector.
(15) Install the fuel filter canister assembly and
torque mounting bolts to 24 N´m (18 ft. lbs.).
(16) Connect fuel lift pump, WIF sensor, and fuel
heater.
(17) Remove the engine lift bracket at rear of cyl-
inder head.
CAUTION: Failure to follow procedure will result in
fuel leaks and/or fuel system failure.
(18)Install the fuel rail and high pressure
fuel lines as follows:
(a) Hand tighten fuel rail bolts.
(b) Hand tighten fuel drain line to pressure lim-
iting valve. Hand tighten banjo bolt at fuel filter
housing.
(c) Hand tighten fuel rail-to-cylinder head high
pressure fuel lines.(d) Install fuel line brace bolts-to-intake mani-
fold finger tight.
(e) Hand tighten fuel pump to fuel rail line.
(f) Torque fuel line nuts at cylinder head to 30
Nm ( 22 ft. lbs.).
(g) Torque fuel line nuts at fuel rail to 30 Nm
(22 ft. lbs.)
(h) Using a back up wrench, torque fuel pump to
fuel rail line to 37 Nm (27 ft. lbs.). At injection
pump.
(i) Torque fuel pump to fuel rail line to 37 Nm
(27 ft. lbs.) at fuel rail.
(j) Torque fuel drain banjo bolt at pressure lim-
iting valve and front of fuel filter housing to 24 Nm
(18 ft. lbs.).
(k) Torque fuel line brace bolts to 24 N´m (18 ft.
lbs.).
(l) Torque rail bolts to 24 Nm (18 ft. lbs.).
(m) Connect fuel pressure sensor.
(19) Install the engine lift bracket at the rear of
cylinder head. Torque to 77 N´m (57 ft. lbs.).
(20) Reposition number 6 fuel line shield and
torque to 43 N´m (32 ft. lbs.).
(21) Install the fuel filter to injection pump low
pressure line. Inspect and replace sealing washers if
necessary. Torque banjo bolts to 24 N´m (18 ft. lbs.).
(22) Connect fuel return line at back of cylinder
head hand tight.
(23) Connect fuel return line at filter housing hand
tight.
(24) Torque banjo connections at cylinder head and
fuel filter housing to 24 Nm (18 ft. lbs.)
(25) Install bracket to rear of filter housing.
Torque to 24 Nm (18 ft. lbs.).
(26) Using new gaskets, install the intake grid
heater and air inlet housing. Torque bolts to 24 N´m
(18 ft. lbs.).
(27) Install wire harness P-clip and push on clip to
air inlet housing.
(28) Connect engine oil level indicator tube at fuel
filter housing and at air inlet housing.
(29) Connect the APPS connector.
(30) Install the APPS assembly to the cylinder
head bracket and torque bolts to 24 N´m (18 ft. lbs.).
(31) Install the throttle linkage cover.
(32) Install the charge air cooler-to-air inlet hous-
ing duct assembly. Torque all clamps to 11 N´m (100
in. lbs.).
(33) Connect intake grid heater wires.
(34) Secure engine harness to front of cylinder
head with bolt at four locations.
(35) Connect engine coolant temperature sensor
connector.
(36) Connect radiator upper hose to thermostat
housing.
Fig. 20 Rocker Arm and Pedestal Removal
1 - ROCKER ARM
2 - PEDESTAL
9 - 254 ENGINE 5.9L DIESELDR
CYLINDER HEAD (Continued)

(37) Rotate generator into position. Install upper
bolt and torque upper and lower bolts.
(38)
Install wire harness push-on clip below bracket.
(39) Install wire harness P-clip to top of bracket.
(40) Install fan support and torque to 32 N´m (24
ft. lbs.).
(41) Install cooling fan/drive refer to (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
(42) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(43) Install exhaust manifold/turbocharger assem-
bly, using new gaskets. Start all bolts/spacers by
hand. Torque bolts to 43 N´m (32 ft. lbs.).
(44) Install exhaust manifold heat shield to
exhaust manifold studs. Install retaining nuts.Torque
to 15 N´m (11 ft. lbs.).
(45) Install exhaust bolt retention straps across
cylinders5&6.
(46) Connect turbocharger oil drain tube. Torque
clamp to 8 N´m (71 in. lbs.).
(47) Perform the turbocharger pre-lube procedure.
Refer to Group 11, Exhaust System and Turbo-
charger for the correct procedure.
(48) Connect the turbocharger oil supply line.
Torque to 24 N´m (18 ft. lbs.).
(49) Install air cleaner housing and duct.
(50) Connect air inlet temperature/pressure sensor.
(51) Raise vehicle on hoist.
(52) Install exhaust pipe to turbocharger elbow.
Torque bolts to 11 N´m (100 in. lbs.).
(53) Lower vehicle.
(54) Fill engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(55) Start engine and check for leaks.
CYLINDER HEAD COVER(S)
REMOVAL
REMOVALÐCYLINDER HEAD COVER
(1) Disconnect both battery negative cables.
(2) Remove oil fill cap.
(3) Remove the breather cover.
(4) Disconnect the breather hose and breather
drain tube from the breather housing.
(5) Remove cylinder head cover bolts.
(6) Remove the cylinder head cover.
REMOVALÐROCKER HOUSING
(1) Remove cylinder head cover as outlined in this
section.
(2) Disconnect rocker housing injector harness con-
nectors.(3) Remove injector harness nuts from injectors.
(4) Remove rocker housing bolts.
(5) Remove rocker housing and gasket.
CLEANING
Using a suitable solvent, Clean and dry gasket
mating surfaces on cylinder head and rocker housing.
Wipe gasket dry and inspect for re-use.
INSPECTION
The cylinder head cover gasket and rocker hous-
ing gasket, are reusable.However, should cracks,
nicks, or tears be present in the rubber/silicone construc-
tion, the defective components should be replaced. Also
replace gasket if it is no longer flexible. Inspect o-rings
on cylinder head cover bolts.Do not reuse gasket if it
has been removed from the groove in the rocker
housing or cylinder head cover.
INSTALLATION
INSTALLATIONÐCYLINDER HEAD COVER
(1) Inspect cylinder head cover gasket for cuts and
proper installation in groove. Replace if damaged.
(2)
Position cylinder cover on top of rocker housing.
(3) Install bolts.
(4) Starting with the center bolt, torque to 24 N´m
(18 ft. lbs.).
(5) Install breather hose to breather.
(6) Install breather drain hose to breather.
(7) Install breather cover and wire harness clip.
Torque to 24 N´m (18 ft. lbs.).
INSTALLATION - ROCKER HOUSING
(1) Inspect rocker housing gasket for cuts, nicks,
or tears. Replace if damaged or if gasket has come
out of groove.
(2) Inspect rocker housing gasket for proper instal-
lation in groove. Gasket bead must be centered in
groove. A gasket bead that is tilted to the side will
cause an oil leak.
CAUTION: When installing rocker housing onto cyl-
inder head, do not slide housing from side to side,
The gasket could fall out or be damaged.
(3) Install the rocker housing. Carefully guide the
rocker housing evenly down onto the cylinder head.
(4) Install rocker housing bolts and tighten finger
tight.
(5) Torque bolts, working from center out, to 24
Nm (18ft. lbs.).
(6) Install injector harness nuts to injector sole-
noid. Torque to 1.25 Nm (11 in. lbs.).
(7) Connect rocker housing injector harness con-
nections.
DRENGINE 5.9L DIESEL 9 - 255
CYLINDER HEAD (Continued)