Drive belt removal DODGE RAM 1500 1998 2.G Manual Online

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)

(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)

(7) With the engine in this position, valve lash can
be measured at the remaining rocker arms:INTAKE
3±5±6 / EXHAUST 2±4±6. Use the same method as
above for determining whether adjustment is neces-
sary, and adjust those that are found to be outside of
the limits.
(8) Install the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(9) Connect the battery negative cables.
REMOVAL - VALVE SPRINGS AND SEALS
(1) Disconnect the battery negative cables.
(2) Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(3) Disconnect rocker housing injector harness con-
nector. Remove all injector harness solenoid nuts.
(4) Remove injector(s) for cylinder(s) to be serviced.
Refer to Group 14 for injector removal.
(5) Remove the rocker housing.
(6) Remove the rocker arms and crossheads from
the cylinder(s) to be serviced. Mark each component
so they can be installed in their original position.
(7) Using the crankshaft barring tool #7471±B
(Fig. 33), rotate the engine to position the damper
mark in the 12 o'clock position.At this engine posi-
tion, cylinders #1 and #6 can be serviced.
(8) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(9) With the damper TDC mark in the 12 o'clock
position, add a paint mark anywhere on the gear
housing cover next to the crankshaft damper. Place
another mark on the vibration damper in alignment
with the mark you just made on the cover.(10) Divide the crankshaft damper into three
equally sized segments as follows:
(a) Using a tape measure, measure the circum-
ference of the crankshaft damper and divide the
measurement by three (3).
(b) Measure that distance in a counter-clockwise
direction from the first balancer mark and place
another mark on the balancer.
(c) From the second damper mark, again mea-
sure in a counter-clockwise direction and place a
mark on the damper at the same distance you
measured when placing the second damper mark.
The damper should now be marked in three
equally spaced locations and the damper TDC
mark should be in the 12 o'clock position.
(d) Remove injectors, fuel lines, and high pres-
sure connectors for every cylinder that requires
repair.
(11) Compress the valve springs at cyls. #1 and #6
as follows:
(a) Install the valve spring compressor mounting
base as shown in (Fig. 34).
(b) Install the top plate, washer, and nut. Using
a suitable wrench tighten the nut (clock-wise) (Fig.
35) to compress the valve springs and remove the
collets.
(c) Rotate the compressor nut counter-clockwise
to relieve tension on springs. Remove spring com-
pressor.
(d) Remove and replace retainers, springs, and
seals as necessary.
(e)Do not rotate the engine until the
springs and retainers are re-installed.
(f) Install seals, springs and retainers. Install
spring compressor, compress valve springs and
install the collets.
Fig. 32 Measuring Valve Lash - Typical
1 - INTAKE
2 - FEELER GAUGE
3 - EXHAUST
Fig. 33 Rotating Engine with Barring Tool - Typical
1 - REAR FLANGE
2 - BARRING TOOL
9 - 260 ENGINE 5.9L DIESELDR
INTAKE/EXHAUST VALVES & SEATS (Continued)

(15) Remove the two charge air cooler mounting
bolts.
(16) Remove charge air cooler (and A/C condenser
if equipped) from vehicle.
(17) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(18) Remove accessory drive belt tensioner.
(19) Remove the fan support/hub assembly.
(20) Remove crankshaft damper and speed indica-
tor ring (Refer to 9 - ENGINE/ENGINE BLOCK/VI-
BRATION DAMPER - REMOVAL).
(21) Remove the gear cover-to-housing bolts and
gently pry the cover away from the housing, taking
care not to mar the sealing surfaces. Remove dust
seal with cover.
(22) Using Special Tool 7471±B Crankshaft Bar-
ring Tool, rotate the crankshaft to align the timing
marks on the crankshaft and the camshaft gears.
(23) Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(24) Remove the rocker arms, cross heads, and
push rods (Fig. 55). Mark each component so they
can be installed in their original positions.
NOTE: The #5 cylinder intake and the #6 cylinder
intake and exhaust pushrods are removed by lifting
them up and through the provided cowl panel
access holes. Remove the rubber plugs to expose
these relief holes.
(25) Raise the tappets as follows, using the wooden
dowel rods (Fig. 57)provided with the Miller Tool Kit
8502.
(a) Insert the slotted end of the dowel rod into
the tappet.The dowel rods for the rear two
cylinders will have to be cut for cowl panel
clearance.Press firmly to ensure that it is seated
in the tappet.(b) Raise the dowel rod to bring the tappet to
the top of its travel, and wrap a rubber band
around the dowel rods (Fig. 57) to prevent the tap-
pets from dropping into the crankcase.
(c) Repeat this procedure for the remaining cyl-
inders.
(26) Verify that the camshaft timing marks are
aligned with the crankshaft mark (Fig. 56).
(27) Remove the bolts from the thrust plate.
(28) Remove engine mount through bolts.
(29) Install engine support fixture special tool #
8534,and steel bracket/wing nut special tool #
8534A.
(30) Raise engine enough to allow camshaft
removal.
(31) Remove the camshaft, gear and thrust plate.
Fig. 55 Push Rod Removal/Installation
Fig. 56 Timing Mark Alignment
Fig. 57 Use Wooden Dowel Rods to Secure Tappets
in Place - Typical
DRENGINE 5.9L DIESEL 9 - 269
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

CRANKSHAFT OIL SEAL - FRONT
REMOVAL
(1) Disconnect both battery negative cables.
(2) Raise vehicle on hoist.
(3) Partially drain engine coolant into container
suitable for re-use (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(4) Lower vehicle.
(5) Remove radiator upper hose.
(6) Disconnect coolant recovery bottle from radia-
tor filler neck and lift bottle off of fan shroud.
(7) Disconnect windshield washer pump supply
hose and electrical connections and lift washer bottle
off of fan shroud.
(8)
Remove the fan shroud-to-radiator mounting bolts.
(9)Remove viscous fan/drive assembly. (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(10) Remove cooling fan shroud and fan assembly
from the vehicle.
(11) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(12) Remove the cooling fan support/hub from the
front of the engine.
(13) Raise the vehicle on hoist.
(14) Remove the crankshaft damper and speed
indicator ring.
(15) Remove power steering pump.
(16) Remove accessory drive belt tensioner.
(17) Remove the gear cover-to-housing bolts and
gently pry the cover away from the housing, taking
care not to mar the gasket surfaces. Remove crank
seal dust shield with cover.
(18) Support the cover on a flat work surface with
wooden blocks (Fig. 68), and using a suitable punch
and hammer, drive the old seal out of the cover from
the back side of the cover to the front side (Fig. 68).
INSTALLATION
(1) Clean cover and housing gasket mating sur-
faces. Use a suitable scraper and be careful not to
damage the gear housing surface. Remove any old
sealer from the oil seal bore. Thoroughly clean the
front seal area of the crankshaft. The seal lip and the
sealing surface on the crankshaft must be free from
all oil residue to prevent seal leaks.
(2) Inspect the gear housing and cover for cracks
and replace if necessary. Carefully straighten any
bends or imperfections in the gear cover with a ball-
peen hammer on a flat surface. Inspect the crank-
shaft front journal for any grooves or nicks that
would affect the integrity of the new seal.
(3) Apply a bead of MopartStud & Bearing Mount
to the outside diameter of the seal. Do not lubricate
the inside diameter of the new seal.(4)
With the cover supported by wood blocks, install
the seal into the rear of the cover using crankshaft seal
installer Special Tool 8281 and driver handle C-4171
(Fig. 69). Strike the driver handle until the installation
tool bottoms out on the inside of the cover.
CAUTION: Do not distort or damage seal.
(5) Install the plastic seal pilot (provided with seal
kit) into the crankshaft seal.
Fig. 68 Removing Seal from Cover
1 - PUNCH
Fig. 69 Installing Seal Into Cover With Tool 8281
1 - SEAL INSTALLER 8281
2 - DRIVER HANDLE C4171
3 - SEAL
DRENGINE 5.9L DIESEL 9 - 275

(6) Apply a bead of MopartSilicone Rubber Adhe-
sive Sealant or equivalent to the gear housing cover
sealing surface.
(7) Install the cover to the gear housing, aligning
the seal pilot with the nose of the crankshaft (Fig.
70).
(8) Install the cover bolts and tighten to 24 N´m
(18 ft. lbs.) torque. Remove pilot tool.
(9) Install dust shield over nose of crankshaft.
(10) Install the crankshaft damper and speed indi-
cator ring. Torque the bolts to 40 N´m (30 ft. lbs.).
Then rotate an additional 60É. Use the engine bar-
ring tool to keep the engine from rotating during
tightening operation.
(11) Install the fan support/hub assembly and
torque bolts to 32 N´m (24 ft. lbs.).
(12) Install power steering pump.
(13) Install accessory drive belt tensioner. Torque
bolt to 43 Nm (32 ft.lbs.).
(14) Install cooling fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
(15) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(16) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(17) Connect battery negative cables.
(18) Start engine and check for oil leaks.
CRANKSHAFT OIL SEAL -
REAR
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the transmission and transfer case (if
equipped).(3) Remove the clutch cover and disc (if manual
transmission equipped) (Refer to 6 - CLUTCH/
CLUTCH DISC - REMOVAL).
(4) Remove the flywheel or converter drive plate.
(5) Drill holes 180É apart into the seal. Be careful
not to contact the drill against the crankshaft.
(6) Install #10 sheet metal screws in the drilled
holes and remove the rear seal with a slide hammer
(Fig. 71).
INSTALLATION
CAUTION: The seal lip and the sealing surface on
the crankshaft must be free from all oil residue to
prevent seal leaks. The crankshaft and seal sur-
faces must be completely dry when the seal is
installed. Use a soap and water solution on outside
diameter of seal to ease assembly.
(1) Clean the crankshaft journal with a suitable
solvent and dry with a clean shop towel or com-
pressed air. Wipe the inside bore of the crankshaft
seal retainer with a clean shop towel.
(2) Inspect the crankshaft journal for gouges,
nicks, or other imperfections. If the seal groove in the
crankshaft is excessively deep, install the new seal
1/8º deeper into the retainer bore, or obtain a crank-
shaft wear sleeve that is available in the aftermar-
ket.
(3) Install the seal pilot and new seal, provided in
the replacement kit, onto the crankshaft.
(4) Remove the seal pilot.
(5) Install the installation tool over crankshaft.
(6) Using a ball peen hammer, strike the tool at
the 12, 3, 6, and 9 o'clock positions until the align-
ment tool bottoms out on the retainer (Fig. 72).
Fig. 70 Installing Front Cover with Seal Pilot
1 - SEAL PILOT
Fig. 71 Crankshaft Rear Seal Removal
1 - NO. 10 SCREW
2 - REAR SEAL
3 - CRANKSHAFT
4 - SLIDE HAMMER
9 - 276 ENGINE 5.9L DIESELDR
CRANKSHAFT OIL SEAL - FRONT (Continued)

(4) The top surface of all of the rings are identified
with the word TOP or the supplier's MARK. Assem-
ble the rings with the word TOP or the supplier's
MARK up.
(5) Position the oil ring expander in the oil control
ring groove (bottom groove).
(6) Install the oil control ring with the end gap
OPPOSITE the ends on the expander (Fig. 95).
(7) Install the intermediate piston ring in the sec-
ond groove.
(8) Install the top piston ring in the top groove
(Fig. 96).
(9) Position the rings as shown in (Fig. 97).
VIBRATION DAMPER
REMOVAL
(1) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).(2) Remove the four (4) damper to crankshaft bolts
and remove damper and speed indicator ring.
INSPECTION
(1) Inspect the damper hub for cracks and replace
if any are found.
(2) Inspect the index lines on the damper hub and
the inertia member (Fig. 98). If the lines are more
than 1.59 mm (1/16 in.) out of alignment, replace the
damper.
(3) Inspect the rubber member for deterioration or
missing segments (Fig. 99).Fig. 95 Oil Control Ring/Expander Location in
Groove
1 - OIL CONTROL RING
2 - EXPANDER
3 - PISTON
Fig. 96 Piston Ring Installation Tool
1 - PISTON RING INSTALLATION TOOL
Fig. 97 Piston Ring Orientation
1 - TOP RING
2 - INTERMEDIATE RING
3 - OIL CONTROL RING
Fig. 98 Inspect Index Lines for Alignment
1 - INDEX LINES
2 - HUB
3 - INERTIA MEMBER
DRENGINE 5.9L DIESEL 9 - 285
PISTON RINGS (Continued)

INSTALLATION
(1) Install speed indicator ring.
NOTE: The speed indicator ring is located over a
dowel pin.
(2) Install the crankshaft damper and bolts.
Tighten bolts to 40 N´m (30 ft. lbs.) torque, plus an
additional 60É.
NOTE: The damper must be installed so the hole is
located over the dowel pin.
(3) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
FRONT MOUNT
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the viscous fan/drive assembly (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
(3) Raise vehicle on hoist.
(4) Install engine support fixture tool# 8534 and
steel bracket tool # 8534A
(5) Loosen the thru-bolt and nut.
(6) Lift the engine SLIGHTLY and remove the
insulator to block bolts (Fig. 101) (Fig. 100).
(7) Remove the insulator from the vehicle.
Fig. 99 Inspect Damper Rubber Member
Fig. 100 RH Insulator
1 - Mount
2 - Insulator
3 - Bolt
Fig. 101 LH Insulator
1 - Bolt
2 - Insulator
3 - Mount
9 - 286 ENGINE 5.9L DIESELDR
VIBRATION DAMPER (Continued)

OIL PRESSURE RELIEF VALVE
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the threaded plug, spring and plunger
(Fig. 108). Insert a finger or a seal pick to lift the
plunger from the bore.
NOTE: If the plunger is stuck in the bore, it will be
necessary to remove the filter head.
CLEANING
(1) Clean the regulator spring and plunger with a
suitable solvent and blow dry with compressed air. If
the plunger bore requires cleaning, it is necessary to
remove the oil filter head to avoid getting debris into
the engine.
INSPECTION
Inspect the plunger and plunger bore for cracks
and excessive wear. Polished surfaces are acceptable.
Verify that the plunger moves freely in the bore.
Check the spring for height and load limitations
(Fig. 109). Replace the spring if out of limits shown
in the figure.
INSTALLATION
(1) Install the plunger, spring, and plug as shown
in (Fig. 108). Tighten the plug to 80 N´m (59 ft. lbs.)
torque.
(2) Connect the battery negative cables.
(3) Start the engine and verify that it has oil pres-
sure.
OIL PRESSURE SWITCH
REMOVAL
(1) Disconnect the battery negative cables.
(2) Disconnect the oil pressure switch connector.
(3) Using a suitable socket, remove the oil pres-
sure switch from the block (counter-clockwise).
INSTALLATION
(1) If the switch is not being replaced, replace and
lubricate the o-ring.
(2) Install the oil pressure switch and tighten to
18 N´m (159 in. lbs.) torque.
(3) Connect oil pressure switch connector.
(4) Connect the battery negative cables.
(5) Start engine and check for oil leaks at the
switch.
OIL PUMP
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove fan/drive assembly (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL).
(3) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(4) Remove the fan support/hub assembly.
(5) Remove crankshaft damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL) and speed indicator ring.
(6) Remove power steering pump.
(7) Remove accessory drive belt tensioner.
(8) Remove the gear housing cover (Refer to 9 -
ENGINE/VALVE TIMING/GEAR HOUSING COVER
- REMOVAL).
Fig. 108 Oil Pressure Regulator
1 - OIL FILTER
2 - PLUG
3 - GASKET
4 - SPRING
5 - VALVE
Fig. 109 Oil Pressure Regulator Spring Check
9 - 294 ENGINE 5.9L DIESELDR

(3) Install heat shield and torque nuts to 15 Nm
(11 ft. lbs.).
(4) Install cab heater tube.
(5) Install exhaust manifold bolt retention straps.
(6) Install the cab heater return hose to the man-
ifold bolt stud. Tighten the nut to 24 N´m (18 ft. lbs.)
torque.
(7) Install the turbocharger and a new gasket.
Apply anti-seize to the studs and then tighten the
turbocharger mounting nuts to 43 N´m (32 ft. lbs.)
torque.
(8)Pre-lube the turbocharger.Pour 50 to 60 cc
(2 to 3 oz.) clean engine oil in the oil supply line fit-
ting on the turbo. Rotate the turbocharger impeller
by hand to distrubute the oil thoroughly.
(9) Install and tighten the oil supply line fitting
nut to 24 N´m (18 ft. lbs.) torque.
(10) Position the charge air cooler inlet pipe to the
turbocharger. With the clamp in position, tighten the
clamp nut to 11 N´m (100 in. lbs.) torque.
(11) Position the air inlet hose to the turbocharger.
Tighten the clamp to 11 N´m (100 in. lbs.) torque.
(12) Raise vehicle on hoist.
(13) Install the oil drain tube and a new gasket to
the turbocharger. Tighten the drain tube bolts to 24
N´m (18 ft. lbs.) torque.
(14) Connect the exhaust pipe to the turbocharger
and tighten the bolts to 11 N´m (100 ft. lbs.) torque.
(15) Lower the vehicle.
(16) Connect the battery negative cables.
(17) Start the engine to check for leaks.
VALVE TIMING
STANDARD PROCEDURE - TIMING
VERIFICATION
(1) Remove the cylinder head cover(Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(2) Remove fuel injector from cylinder number
1(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - REMOVAL).
(3) Using Special Tool 7471B rotate the engine
until the TDC mark on the damper is at 12 o'clock.
(4) Using a 8 in.x 1/4 in. dowel rod inserted into
cylinder number 1, rock the crankshaft back and
forth to verify piston number 1 is at TDC.
(5) With cylinder number still at TDC, inspect the
keyway on the crankshaft gear for proper alignment
(12 o'clock position).
(6) If the keyway is not at 12 o'clock position
replace the crankshaft gear assembly.
(7) If the keyway is at 12 o'clock position, remove
front gear cover and verify timing mark alignmentbetween the camshaft gear and crankshaft gear, if
not aligned inspect keyway on camshaft gear.
(8) Inspect keyway on camshaft gear for proper
alignment with the key in the camshaft, if alignment
is off replace the camshaft/gear assembly.
(9) If timing marks alignment is off and no dam-
age is found at either the crankshaft or camshaft
gear keyways, realign timing marks as necessary.
GEAR HOUSING
REMOVAL
(1) Disconnect the battery negative cables.
(2) Raise vehicle on hoist.
(3) Partially drain engine coolant into container
suitable for re-use (Refer to 7 - COOLING - STAN-
DARD PROCEDURE).
(4) Lower vehicle.
(5) Remove radiator upper hose.
(6) Disconnect coolant recovery bottle hose from
radiator filler neck and lift bottle off of fan shroud.
(7) Disconnect windshield washer pump supply
hose and electrical connections and lift washer bottle
off of fan shroud.
(8) Remove lower fan shroud fasteners. Disconnect
fan drive wire harness.
(9) Remove the upper fan shroud-to-radiator
mounting bolts.
(10) Remove viscous fan/drive assembly (Refer to 7
- COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(11) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(12) Remove the cooling fan support/hub from the
front of the engine.
(13) Raise the vehicle on hoist.
(14) Remove the crankshaft damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL) and speed indicator ring.
(15) Lower the vehicle.
(16) Remove the power steering pump.
(17) Remove the accessory drive belt tensioner.
(18) Remove the gear cover-to-housing bolts and
gently pry the cover away from the housing, taking
care not to mar the gasket surfaces.
(19) Remove the fuel injection pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - REMOVAL).
(20) Disconnect the camshaft position sensor con-
nector.
(21) Disconnect and remove engine speed sensor.
(22) Remove the camshaft (Refer to 9 - ENGINE/
ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - REMOVAL).
(23) Remove the six front oil pan fasteners.
DRENGINE 5.9L DIESEL 9 - 299
EXHAUST MANIFOLD (Continued)