Intake manifold gasket DODGE RAM 1500 1998 2.G Owner's Manual

CAUTION: The head gaskets are marked ªTOPº to
indicate which side goes up.
(4) Position cylinder heads onto head gaskets and
cylinder block.
(5) Tighten the cylinder head bolts in three steps
(Fig. 4):
²Step 1Ð Snug tighten M12 cylinder head bolts,
in sequence, to 34 N´m (25 ft. lbs.) and M8 bolts to
20 N´m (15 ft. lbs.) torque.
²Step 2Ð Tighten M12 cylinder head bolts, in
sequence, to 54 N´m (40 ft. lbs.) and verify M8 bolts
to 20 N´m (15 ft. lbs.) torque..
²Step 3Ð Turn M12 cylinder head bolts, in
sequence, 90 degrees and tighten M8 bolts to 34 N´m
(25 ft. lbs.) torque.
(6) Install push rods and rocker arm assemblies in
their original position.
(7) Install the intake manifold and throttle body
assembly.
(8) If required, adjust spark plugs to specifications.
Install the plugs.
(9) Connect the heater hoses.
(10) Install the fuel supply line.
(11) Install the generator and drive belt.
(12) Install cylinder head covers(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(13) Connect the evaporation control system.
(14) Install the air cleaner.
(15) Fill cooling system.
(16) Connect the negative cable to the battery.
(17) Start engine check for leaks.CYLINDER HEAD COVER(S)
REMOVAL
(1) Disconnect battery negative cable.
(2) Disconnect coil on plug connectors.
CAUTION: The ground straps must be installed in
the same location as removed. The covers are
machined to accept the ground straps in those
locations only.
(3) Remove cylinder head cover retaining bolts,
and ground straps.
(4) Remove cylinder head cover.
NOTE: The gasket may be used again, provided no
cuts, tears, or deformation has occurred.
INSTALLATION
CAUTION: Do not use harsh cleaners to clean the
cylinder head covers. Severe damage to covers
may occur.
CAUTION: DO NOT allow other components includ-
ing the wire harness to rest on or against the
engine cylinder head cover. Prolonged contact with
other objects may wear a hole in the cylinder head
cover.
(1) Clean cylinder head cover and both sealing sur-
faces. Inspect and replace gasket as necessary.
(2)
Install cylinder head cover and hand start all fas-
teners. Verify that all double ended studs are in the cor-
rect location and install left and right ground straps.
CAUTION: The ground straps must be installed in
the same location as removed. The covers are
machined to accept the ground straps in those
locations only.
NOTE: The right hand ground strap is located on
the front inboard stud. The left hand ground strap
is located on the rear inboard stud.
(3) Tighten cylinder head cover bolts and double
ended studs to 8 N´m (70 in. lbs). Begin torque
sequence in the middle of head cover and torque
bolts moving outward in a crisscross pattern from top
to bottom.
(4) Install ignition coil on plug, and torque fasten-
ers to 12 N´m (105 in. lbs)
(5) Connect, ignition coil electrical connectors.
(6) Install PCV hose.
(7) Connect battery negative cable.
Fig. 4 CYLINDER HEAD TIGHTENING SEQUENCE
DRENGINE - 5.7L 9 - 201
CYLINDER HEAD (Continued)

(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)

INSPECTION
Check the connecting rod journal for excessive
wear, taper and scoring (Refer to 9 - ENGINE/EN-
GINE BLOCK/CONNECTING ROD BEARINGS -
STANDARD PROCEDURE).
Check the connecting rod for signs of twist or bend-
ing.
Check the piston for taper and elliptical shape
before it is fitted into the cylinder bore (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON & CONNECT-
ING ROD - STANDARD PROCEDURE).
Check the piston for scoring, or scraping marks in
the piston skirts. Check the ring lands for cracks
and/or deterioration.
INSTALLATION
(1) Before installing piston and connecting rod
assemblies into the bore, install the piston rings(Re-
fer to 9 - ENGINE/ENGINE BLOCK/PISTON RINGS
- STANDARD PROCEDURE).
(2) Immerse the piston head and rings in clean
engine oil. Position a ring compressor over the piston
and rings. Tighten ring compressor.Ensure posi-
tion of rings do not change during this opera-
tion.
(3) Position bearing onto connecting rod. Lubricate
bearing surface with clean engine oil.
(4) Install Special Tool 8507 Connecting Rod
Guides into connecting rod bolt threads.
(5) The pistons are marked on the piston pin bore
surface with an raised ªFº or arrow on top of piston
indicating installation position. This mark must be
pointing toward the front of engine on both cylinder
banks.
(6) Wipe cylinder bore clean and lubricate with
engine oil.
(7) Rotate crankshaft until connecting rod journal
is on the center of cylinder bore. Insert rod and pis-
ton into cylinder bore and carefully position connect-
ing rod guides over crankshaft journal.
(8) Tap piston down in cylinder bore using a ham-
mer handle. While at the same time, guide connect-
ing rod into position on rod journal.
CAUTION: Connecting Rod Bolts are Torque to
Yield Bolts and Must Not Be Reused. Always
replace the Rod Bolts whenever they are loosened
or removed.
(9) Lubricate rod bolts and bearing surfaces with
engine oil. Install connecting rod cap and bearing.
Tighten bolts to 21 N´m (15 ft. lbs.) plus a 90É turn.
(10) Install the following components:
²Cylinder head(s). (Refer to 9 - ENGINE/CYLIN-
DER HEAD - INSTALLATION).²Cylinder head covers (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
INSTALLATION).
²Install the intake manifold.
²Oil pan and gasket/windage tray. (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
(11) Fill crankcase with proper engine oil to cor-
rect level.
(12) Connect negative cable to battery.
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING
Before reinstalling used rings or installing new
rings, the ring clearances must be checked.
(1) Wipe the cylinder bore clean.
(2) Insert the ring in the cylinder bore.
NOTE: The ring gap measurement must be made
with the ring positioned at least 12mm (0.50 inch.)
from bottom of cylinder bore.
(3) Using a piston, to ensure that the ring is
squared in the cylinder bore, slide the ring downward
into the cylinder.
(4) Using a feeler gauge check the ring end gap
(Fig. 13). Replace any rings not within specification.
PISTON RING SIDE CLEARANCE
NOTE: Make sure the piston ring grooves are clean
and free of nicks and burrs.
Fig. 13 Ring
1 - FEELER GAUGE
DRENGINE - 5.7L 9 - 213
PISTON & CONNECTING ROD (Continued)

OIL PAN
REMOVAL
(1) Disconnect the negative battery cable.
(2) Install engine support fixture special tool #
8534.Do not raise engine at this time.
(3) Loosen both left and right side engine mount
through bolts. Do not remove bolts.
(4) Remove the structural dust cover, if equipped.
(5) Drain engine oil.
(6) Remove the front crossmember(Refer to 13 -
FRAME & BUMPERS/FRAME/FRONT CROSS-
MEMBER - REMOVAL).
CAUTION: Only raise the engine enough to provide
clearance for oil pan removal. Check for proper
clearance at fan shroud to fan and cowl to intake
manifold.
(7) Raise engine using special tool # 8534 to pro-
vide clearance to remove oil pan.
NOTE: Do not pry on oil pan or oil pan gasket. Gas-
ket is integral to engine windage tray and does not
come out with oil pan.
(8) Remove the oil pan mounting bolts and oil pan.
NOTE: The double ended oil pan studs must be
installed in the same location that they were
removed from.
(9) Unbolt oil pump pickup tube and remove tube.
(10) Inspect the integral windage tray and gasket
and replace as needed.
INSTALLATION
(1) Clean the oil pan gasket mating surface of the
block and oil pan.
(2) Inspect the integral windage tray and gasket
and replace as needed.
(3) Reinstall the oil pump pickup tube with new
o-ring. Tighten tube to pump fasteners to 28 N´m
(250 in. lbs.).
NOTE: The double ended oil pan studs must be
installed in the same location that they were
removed from.
(4) Position the oil pan and install the mounting
bolts and studs.. Tighten the mounting bolts to 12
N´m (105 in.lbs.).
(5) Lower the engine into mounts using special
tool # 8534.
(6) Install both the left and right side engine
mount through bolts. Tighten the nuts to 68 N´m (50
ft. lbs.).(7) Remove special tool # 8534.
(8) Install structural dust cover, if equipped.
(9) Install the front crossmember(Refer to 13 -
FRAME & BUMPERS/FRAME/FRONT CROSS-
MEMBER - INSTALLATION).
(10) Fill engine oil.
(11) Reconnect the negative battery cable.
(12) Start engine and check for leaks.
OIL PUMP
REMOVAL
(1) Remove the oil pan and pick-up tube(Refer to 9
- ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(2) Remove the timing chain cover(Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(3) Remove the four bolts, and the oil pump.
CLEANING
(1) Wash all parts in a suitable solvent.
INSPECTION
CAUTION: Oil pump pressure relief valve and
spring should not be removed from the oil pump. If
these components are disassembled and or
removed from the pump the entire oil pump assem-
bly must be replaced.
(1) Remove the pump cover.
(2) Clean all parts thoroughly. Mating surface of
the oil pump housing should be smooth. If the pump
cover is scratched or grooved the oil pump assembly
should be replaced.
(3) Slide outer rotor into the body of the oil pump.
Press the outer rotor to one side of the oil pump body
and measure clearance between the outer rotor and
the body (Fig. 30). If the measurement is 0.235mm
(0.009 in.) or more the oil pump assembly must be
replaced.
(4) Install the inner rotor in the into the oil pump
body. Measure the clearance between the inner and
outer rotors (Fig. 31). If the clearance between the
rotors is .150 mm (0.006 in.) or more the oil pump
assembly must be replaced.
(5) Place a straight edge across the body of the oil
pump (between the bolt holes), if a feeler gauge of
.095 mm (0.0038 in.) or greater can be inserted
between the straightedge and the rotors, the pump
must be replaced (Fig. 32).
(6) Reinstall the pump cover. Torque fasteners to
15 N´m (132 in. lbs.).
9 - 224 ENGINE - 5.7LDR

NOTE: The 5.7 Oil pump is released as an assem-
bly. There are no DaimlerChrysler part numbers for
Sub-Assembly components. In the event the oil
pump is not functioning or out of specification it
must be replaced as an assembly.
INSTALLATION
(1) Position the oil pump onto the crankshaft and
install the 4 oil pump retaining bolts.(2) Tighten the oil pump retaining bolts to 28 N´m
(250 in. lbs.).
(3) Install the timing chain cover(Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(4) Install the pick-up tube and oil pan(Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
INTAKE MANIFOLD
DESCRIPTION
The intake manifold is made of a composite mate-
rial and features long runners which maximizes low
end torque. The intake manifold uses single plane
sealing which consist of eight individual press in
place port gaskets to prevent leaks.
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKAGE
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water at the suspected
leak area.
(3) If a change in RPM is observed the area of the
suspected leak has been found.
(4) Repair as required.
Fig. 30 Measuring Outer Rotor Clearance
1 - FEELER GAUGE
2 - OUTER ROTOR
Fig. 31 Measuring Clearance Between Rotors -
Typical
1 - OUTER ROTOR
2 - FEELER GAUGE
3 - INNER ROTOR
Fig. 32 Measuring Clearance Over Rotors - Typical
1 - STRAIGHT EDGE
2 - FEELER GAUGE
DRENGINE - 5.7L 9 - 225
OIL PUMP (Continued)

REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove resonator assembly and air inlet hose.
(3) Disconnect electrical connectors for the follow-
ing components:
²Manifold Absolute Pressure (MAP) Sensor
²Intake Air Temperature (IAT) Sensor
²Throttle Position (TPS) Sensor
²Coolant Temperature (CTS) Sensor
(4) Disconnect brake booster hose and positive
crankcase ventilation (PCV) hose.
(5) Remove generator and set aside.
NOTE: It is not necessary to remove lines or
remove freon from A/C compressor.
(6) Remove air conditioning compressor and set
aside..
(7) Bleed fuel system (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY - STANDARD PROCE-
DURE).
(8) Remove intake manifold retaining fasteners in
a crisscross pattern starting from the outside bolts
and ending at the middle bolts.
(9) Remove intake manifold and IAFM as an
assembly.
CLEANING
NOTE: There is NO approved repair procedure for
the intake manifold. If severe damage is found dur-
ing inspection, the intake manifold must be
replaced.
Before installing the intake manifold thoroughly
clean the mating surfaces. Use a suitable cleaning
solvent, then air dry.
INSPECTION
(1) Inspect the intake sealing surface for cracks,
nicks and distortion.
(2) Inspect the intake manifold vacuum hose fit-
tings for looseness or blockage.
(3) Inspect the manifold to throttle body mating
surface for cracks, nicks and distortion.
INSTALLATION
(1) Install intake manifold seals.
(2) Position intake manifold and IAFM.
(3) Install intake manifold retaining bolts, and
tighten in sequence from the middle bolts towards
the outside in a crisscross pattern. Torque fasteners
to 12 N´m (105 in. lbs.).
(4) Connect electrical connectors for the following
components:
²Manifold Absolute Pressure (MAP) Sensor
²Intake Air Temperature (IAT) Sensor²Throttle Position (TPS) Sensor
²Coolant Temperature (CTS) Sensor
²Idle Air Control (IAC) Motor
(5) Install generator.
(6) Install A/C compressor.
(7) Connect Brake booster hose and Positive crank-
case ventilation (PCV) hose.
(8) Install resonator assembly and air inlet hose.
(9) Connect negative cable to battery.
EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifolds are log style with a pat-
ented flow enhancing design to maximize perfor-
mance. The exhaust manifolds are made of high
silicon molybdenum cast iron. A perforated core
graphite exhaust manifold gasket is used to improve
sealing to the cylinder head. The exhaust manifolds
are covered by a three layer laminated heat shield
for thermal protection and noise reduction. The heat
shields are fastened with a torque prevailing nut
that is backed off slightly to allow for the thermal
expansion of the exhaust manifold.
OPERATION
The exhaust manifolds collect the engine exhaust
exiting the combustion chambers, then channels the
exhaust gases to the exhaust pipes attached to the
manifolds.
REMOVAL
EXHAUST MANIFOLD
(1) Disconnect negative battery cable.
(2) Raise vehicle.
(3) Remove exhaust pipe to manifold bolts.
(4) Lower vehicle.
(5) Install engine support fixture special tool
#8534.
(6) Raise engine enough to remove manifolds.
CAUTION: Do not damage engine harness while
raising the engine.
(7) Remove heat shield.
(8) Remove manifold bolts.
(9) Remove manifold and gasket.
CLEANING
Clean mating surfaces on cylinder head and mani-
fold. Wash with solvent and blow dry with com-
pressed air.
9 - 226 ENGINE - 5.7LDR
INTAKE MANIFOLD (Continued)

CRANKSHAFT OIL SEAL - FRONT
REMOVAL............................275
INSTALLATION........................275
CRANKSHAFT OIL SEAL - REAR
REMOVAL............................276
INSTALLATION........................276
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL............................277
INSTALLATION........................277
SOLID LIFTERS/TAPPETS
REMOVAL............................279
CLEANING...........................279
INSPECTION.........................279
INSTALLATION........................280
PISTON & CONNECTING ROD
DESCRIPTION........................281
STANDARD PROCEDURE - HEAD GASKET
SELECTION.........................281
REMOVAL............................281
CLEANINGÐPISTON AND CONNECTING
ROD ..............................282
INSPECTION
INSPECTION - PISTONS...............282
INSPECTIONÐCONNECTING ROD.......283
INSTALLATION........................283
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING............................284
VIBRATION DAMPER
REMOVAL............................285
INSPECTION.........................285
INSTALLATION........................286
FRONT MOUNT
REMOVAL............................286
INSTALLATION........................287
REAR MOUNT
REMOVAL............................288
INSTALLATION........................288
LUBRICATION
DESCRIPTION........................289
OPERATION..........................289
DIAGNOSIS AND TESTINGÐENGINE OIL
PRESSURE.........................289
OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL
LEVEL.............................292STANDARD PROCEDURE - ENGINE OIL
SERVICE...........................292
OIL COOLER & LINES
CLEANING
CLEANING AND INSPECTION...........293
OIL FILTER
REMOVAL............................293
INSTALLATION........................293
OIL PAN
REMOVAL............................293
CLEANING...........................293
INSPECTION.........................293
INSTALLATION........................293
OIL PRESSURE RELIEF VALVE
REMOVAL............................294
CLEANING...........................294
INSPECTION.........................294
INSTALLATION........................294
OIL PRESSURE SWITCH
REMOVAL............................294
INSTALLATION........................294
OIL PUMP
REMOVAL............................294
CLEANING...........................295
INSPECTION.........................295
INSTALLATION........................296
INTAKE MANIFOLD
REMOVAL............................297
CLEANING...........................297
INSPECTION.........................297
INSTALLATION........................298
EXHAUST MANIFOLD
REMOVAL............................298
CLEANING...........................298
INSPECTION.........................298
INSTALLATION........................298
VALVE TIMING
STANDARD PROCEDURE - TIMING
VERIFICATION.......................299
GEAR HOUSING
REMOVAL............................299
INSTALLATION........................300
GEAR HOUSING COVER
REMOVAL............................301
INSTALLATION........................301
DRENGINE 5.9L DIESEL 9 - 231

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)

(13) Install the cooling fan (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION).
(14) Connect battery negative cables.
(15) Start engine and check for oil leaks.
INTAKE MANIFOLD
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the charge air cooler outlet tube from
the air inlet housing (Fig. 118).
(3) Remove the engine oil dipstick tube mounting
bolt (Fig. 118).
(4) Remove dipstick support at fuel filter housing.
Position dipstick tube to the side.
(5) Disconnect the air grid heater power cables at
the cable mounting studs.
(6) Disconnect the ground strap at the intake
cover.
(7) Remove the engine wiring harness connections
at the air inlet housing elbow.
(8) Remove the four (4) air inlet housing mounting
bolts and remove the housing from top of the heater
elements.
(9) Remove the intake air grid heater from the
manifold (Fig. 119).
(10) Remove the high pressure fuel lines and fuel
rail (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL LINES - REMOVAL).
(11) Remove APPS bracket from cylinder head to
gain access to front intake manifold cover bolts.
(12) Disconnect manifold air temperature/pressure
sensor connector.
(13) Remove the remaining intake manifold cover-
to-cylinder head bolts.
(14) Remove the intake manifold cover and gasket.
Keep the gasket material and any other material out
of the air intake.
(15) Clean the intake manifold cover and cylinder
head sealing surface.
CLEANING
Clean manifold in solvent and blow dry with com-
pressed air.
Clean cylinder block gasket surfaces using a suit-
able 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.
Fig. 118 Charge Air Cooler Air Tube
1 - FRONT WIRING CLIP
2 - GROUND CABLE
3 - TUBE BOLT
4 - ENGINE OIL DIPSTICK TUBE
5 - CLAMPS
6 - AIR TUBE (INT. MAN.-TO-INTERCOOLER)
7 - RUBBER HOSE
8 - AIR INTAKE HOUSING
9 - CABLE BRACKET HOUSING
Fig. 119 Intake Air Grid Heater
1 - INTAKE AIR GRID HEATER
2 - GASKET
DRENGINE 5.9L DIESEL 9 - 297
OIL PUMP (Continued)

INSTALLATION
(1) Using a new gasket, install the intake manifold
cover.
(2) Install the cover-to-cylinder head bolts that do
not hold down the fuel rail. Tighten the bolts to 24
N´m (18 ft. lbs.) torque.
(3) Install the high pressure rail and fuel lines
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL LINES - INSTALLATION).
(4) Using two (2) new gaskets, install the intake
air grid heater and air inlet housing. Position the
ground cable and install and tighten the bolts to 24
N´m (18 ft. lbs.) torque.
(5) Connect the manifold air temperature/pressure
sensor connector.
(6) Install and tighten the air intake heater power
supply nuts to 14 N´m (120 in. lbs.) torque.
(7) Install the APPS bracket. Torque fasteners to
43 N´m (32ft lbs.) torque.
(8) Install oil dipstick tube support at fuel filter
housing.
(9) Install the engine oil dipstick tube and mount-
ing bolt.
(10) Position the charge air cooler outlet tube onto
the air inlet housing. Tighten the clamps to 11 N´m
(100 in. lbs.) torque.
(11) Attach the engine wire harness to the air inlet
housing at two locations.
(12) Prime the fuel system. Refer to the fuel prim-
ing procedure in Group 14, Fuel System.
(13) Connect the battery negative cables.
EXHAUST MANIFOLD
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Disconnect the exhaust pipe from the turbo-
charger elbow.
(4) Disconnect oil drain tube from turbocharger.
(5) Lower vehicle.
(6) Disconnect the turbocharger air inlet hose.
(7) Remove air cleaner assembly.
(8) Disconnect the turbocharger oil supply line.
(9) Disconnect the charge air cooler inlet pipe from
the turbocharger.
(10) Remove the turbocharger and gasket from the
exhaust manifold.
(11) Remove the cab heater return pipe nuts from
the exhaust manifold stud. Position the tube out of
the way.
(12) Remove heat shield.
(13) Remove exhaust manifold bolt lockplates.
(14) Remove the exhaust manifold-to-cylinder head
bolts and spacers (Fig. 120).(15) Remove the exhaust manifold and gaskets
(Fig. 120).
CLEANING
Clean the cylinder head and exhaust manifold seal-
ing surfaces with a suitable scraper. Use a Scotch-
BriteŸ pad or equivalent.
INSPECTION
Inspect the exhaust manifold for cracks. Measure
the exhaust manifold for flatness. Place a ruler over
all of the exhaust ports and insert a feeler gauge
between the port flange and the ruler. Maximum
deviation from flat is 0.20 mm (.008 inch).
INSTALLATION
(1) Using new gaskets, install the exhaust mani-
fold and gaskets. Install the bolts and spacers and
tighten the bolts in the sequence shown in to 43 N´m
(32 ft. lbs.) torque.
(2) Retorque the four center bolts.
Fig. 120 Exhaust Manifold and Gaskets
1 - RETAINING STRAP
2 - BOLT (7)
3 - SPACER
4 - MANIFOLD, EXHAUST
5 - GASKET
6 - BOLT (5)
9 - 298 ENGINE 5.9L DIESELDR
INTAKE MANIFOLD (Continued)