engine oil DODGE RAM 2001 Service Repair Manual

LUBRICATION
DESCRIPTION..........................292
OPERATION............................292
DIAGNOSIS AND TESTING................295
ENGINE OIL PRESSURE................295
OIL
STANDARD PROCEDURE.................295
ENGINE OIL LEVEL....................295
ENGINE OIL SERVICE..................295
OIL COOLER & LINES
CLEANING.............................296
OIL FILTER
REMOVAL.............................296
INSTALLATION..........................296
OIL PAN
REMOVAL.............................296
CLEANING.............................297
INSPECTION...........................297
INSTALLATION..........................297
OIL PRESSURE RELIEF VALVE
REMOVAL.............................297
CLEANING.............................297
INSPECTION...........................297
INSTALLATION..........................298
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION..........................298OPERATION............................298
REMOVAL.............................298
INSTALLATION..........................299
OIL PUMP
REMOVAL.............................299
CLEANING.............................299
INSPECTION...........................299
INSTALLATION..........................300
INTAKE MANIFOLD
REMOVAL.............................301
CLEANING.............................302
INSPECTION...........................302
INSTALLATION..........................302
EXHAUST MANIFOLD
REMOVAL.............................303
CLEANING.............................304
INSPECTION...........................304
INSTALLATION..........................304
GEAR HOUSING
REMOVAL.............................304
INSTALLATION..........................305
GEAR HOUSING COVER
REMOVAL.............................306
INSTALLATION..........................307
9 - 230 ENGINE 5.9L DIESELBR/BE

ENGINE 5.9L DIESEL
DESCRIPTION
The cylinder block is constructed of cast iron. The
casting is a skirted design which incorporates longi-
tudal ribs for superior strength and noise reduction.
The block incorporates metric straight thread o-ring
fittings at lubrication oil access points. The engine is
manufactured with the cylinders being a non-sleeved
type cylinder. However, one approved service method
is to bore out the cylinders and add cylinder sleeves
to the cylinder block.
The cylinders are numbered front front to rear
(Fig. 1); 1 to 6. The firing order is 1±5±3±6±2±4.
CumminsT24 Valve Turbo Diesel Engine
Fig. 1 Cylinder Numbering
BR/BEENGINE 5.9L DIESEL 9 - 231

DIAGNOSIS AND TESTINGÐENGINE DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTION
LUBRICATING OIL
PRESSURE LOW1. Low oil level. 1. (a) Check and fill with clean engine oil.
(b) Check for a severe external oil leak that
could reduce the pressure.
2. Oil viscosity thin, diluted or wrong
specification.2. Verify the correct engine oil is being
used. (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
3. Improperly operating pressure
switch/gauge.3. Verify the pressure switch is functioning
correctly. If not, replace switch/gauge.
4. Relief valve stuck open. 4. Check/replace valve.
5. Plugged oil filter. 5. Change oil filter.
6. If cooler was replaced, shipping
plugs may have been left in cooler6. Check/remove shipping plugs.
7. Worn oil pump. 7. Check and replace oil pump.
8. Suction tube loose or seal leaking. 8. Check and replace seal.
9. Loose main bearing cap. 9. Check and install new bearing. Tighten
cap to proper torque.
10. Worn bearings or wrong bearings
installed.10. Inspect and replace connecting rod or
main bearings. Check and replace piston
cooling nozzles.
11. Oil jet under piston bad fit into
main carrier.11. Check oil jet position.
LUBRICATING OIL
PRESSURE TOO HIGH1. Pressure switch/gauge not
operating properly.1. Verify pressure switch is functioning
correctly. If not, replace switch/gauge.
2. Engine running to cold. 2. Refer to Coolant Temperature Below
Normal (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
3. Oil viscosity too thick. 3. Make sure the correct oil is being used.
(Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
4. Oil pressure relief valve stuck
closed or binding4. Check and replace valve.
LUBRICATING OIL LOSS 1. External leaks. 1. Visually inspect for oil leaks. Repair as
required.
2. Crankcase being overfilled. 2. Verify that the correct dipstick is being
used.
3. Incorrect oil specification or
viscosity.3. (a) Make sure the correct oil is being
used (Refer to LUBRICATION &
MAINTENANCE/FLUID TYPES -
DESCRIPTION).
(b) Look for reduced viscosity from dilution
with fuel.
(c) Review/reduce oil change intervals.
9 - 232 ENGINE 5.9L DIESELBR/BE
ENGINE 5.9L DIESEL (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
4. Oil cooler leak 4. Check and replace the oil cooler.
5. High blow-by forcing oil out the
breather.5. Check the breather tube area for signs of
oil loss. Perform the required repairs.
6. Turbocharger leaking oil to the air
intake.6. Inspect the air ducts for evidence of oil
transfer. Repair as required.
7. Piston rings not sealing (oil being
consumed by the engine).7. Perform blow-by check. Repair as
required.
COMPRESSION KNOCKS 1. Air in the fuel system. 1. Bleed the fuel system (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
2. Poor quality fuel or water/gasoline
contaminated fuel.2. Verify by operating from a temporary
tank with good fuel. Clean and flush the
fuel tank. Replace fuel/water separator filter.
3. Engine overloaded. 3. Verify the engine load rating is not being
exceeded.
4. Incorrect injection pump timing. 4. Check injection pump for proper
installation.
5. Improperly operating injectors. 5. Check and replace inoperative injectors.
EXCESSIVE VIBRATION 1. Loose or broken engine mounts. 1. Replace engine mounts.
2. Damaged fan or improperly
operating accessories.2. Check and replace the vibrating
components.
3. Improperly operating vibration
damper3. Inspect/replace vibration damper.
4. Improperly operating viscous fan
drive.4. Inspect/replace fan drive.
5. Worn or damaged generator
bearing.5. Check/replace generator.
6. Flywheel housing misaligned. 6. Check/correct flywheel alignment.
7. Loose or broken power
component.7. Inspect the crankshaft and rods for
damage that causes an unbalance
condition. Repair/replace as required.
8. Worn or unbalanced driveline
components.8. Check/repair driveline components.
EXCESSIVE ENGINE
NOISES1. Drive belt squeal, insufficient
tension or abnormally high loading.1. Check the automatic tensioner and
inspect the drive belt. Make sure water
pump, tensioner pulley, fan hub and
generator turn freely.
2. Intake air or exhaust leaks. 2. Refer to Excessive Exhaust Smoke
(Refer to 9 - ENGINE - DIAGNOSIS AND
TESTING).
3. Excessive valve lash. 3. Adjust valves. Make sure the push rods
are not bent and rocker arms, adjusting
screws, crossheads, are not severely worn.
Replace bent or severely worn components.
BR/BEENGINE 5.9L DIESEL 9 - 233
ENGINE 5.9L DIESEL (Continued)

EXCESSIVE WHITE SMOKE
POSSIBLE CAUSE CORRECTION
Fuel injector protrusion not correct. Check washer (shim) at bottom of fuel injector for
correct thickness. (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/FUEL INJECTOR - INSTALLATION)
Fuel injection pump malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Fuel supply side restriction to transfer pump. Refer to Fuel Transfer Pump Pressure (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL TRANSFER
PUMP - DIAGNOSIS AND TESTING)
Fuel transfer (lift) pump malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information. Also refer to Fuel
Transfer Pump Pressure Testing (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL TRANSFER PUMP -
DIAGNOSIS AND TESTING).
Intake/Exhaust valve adjustments not correct (too tight). (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/
EXHAUST VALVES & SEATS - STANDARD
PROCEDURE).
Intake manifold air temperature sensor malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Intake manifold heater circuit not functioning correctly in
cold weather.A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information. Also check heater
elements for correct operation.
Intake manifold heater elements not functioning
correctly in cold weather.A diagnostic trouble code WILL NOT BE SET if heater
elements are malfunctioning. Refer to NTC tests in
Powertrain Diagnostic Procedures Information.
Internal engine damage (scuffed cylinder). Analyze engine oil and inspect oil filter to locate area of
probable damage.
Restriction in fuel supply side of fuel system. Refer to Fuel Transfer Pump Pressure Testing (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL
TRANSFER PUMP - DIAGNOSIS AND TESTING).
Static timing incorrect. A DTC should have been set. If so, (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJECTION
PUMP - DIAGNOSIS AND TESTING).
EXCESSIVE BLUE SMOKE
POSSIBLE CAUSE CORRECTION
Dirty air cleaner or restricted turbocharger intake duct. Check Filter MinderTat air filter housing. (Refer to 9 -
ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
ELEMENT - REMOVAL).
Air leak in boost system between turbocharger
compressor outlet and intake manifold.Service air charge system..
Obstruction in exhaust manifold. Remove exhaust manifold and inspect for blockage
(Refer to 9 - ENGINE/MANIFOLDS/EXHAUST
MANIFOLD - REMOVAL).
Restricted turbocharger drain tube. Remove turbocharger drain tube and remove
obstruction.
Crankcase ventilation system plugged. Inspect crankcase breather and vent tube for sludge
formation or obstructions.
9 - 236 ENGINE 5.9L DIESELBR/BE
ENGINE 5.9L DIESEL (Continued)

EXCESSIVE BLUE SMOKE
POSSIBLE CAUSE CORRECTION
Valve seals are worn, brittle, or improperly installed. Replace valve stem oil seals (Refer to 9 - ENGINE/
CYLINDER HEAD/INTAKE/EXHAUST VALVES &
SEATS - REMOVAL).
Valve stems and/or guides are worn. Remove valves and inspect valves and guides. (Refer
to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
Broken or Improperly installed piston rings. Tear down engine and inspect piston rings.
Excessive piston ring end gap. Remove pistons and measure piston ring end gap
(Refer to 9 - ENGINE/ENGINE BLOCK/PISTON RINGS
- STANDARD PROCEDURE).
Excessive cylinder bore wear and taper. Remove pistons and measure cylinder bore wear and
taper (Refer to 9 - ENGINE/ENGINE BLOCK -
STANDARD PROCEDURE).
Cylinder damage. Remove pistons and inspect cylinder bore for cracks or
porosity. Repair with cylinder liner if necessary. (Refer
to 9 - ENGINE/ENGINE BLOCK - STANDARD
PROCEDURE).
Piston damage. Remove pistons and inspect for cracks, holes. Measure
piston for out-of-round and taper (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON & CONNECTING
ROD - INSPECTION).
Turbocharger failure. (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER - INSPECTION).
STANDARD PROCEDUREÐFORM-IN-PLACE
GASKETS & SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN II
MopartEngine RTV GEN II is used to seal com-
ponents exposed to engine oil. This material is a spe-
cially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
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. Alwaysinspect 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-
BR/BEENGINE 5.9L DIESEL 9 - 237
ENGINE 5.9L DIESEL (Continued)

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 then 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 PROCEDUREÐREPAIR 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 a breaker bar and socket.
(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 new fuel injectors (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/FUEL INJECTOR -
INSTALLATION).
(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 34
N´m (25 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.
REMOVALÐENGINE
(1) Disconnect both battery negative cables.
(2) Recover A/C refrigerant (if A/C equipped) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE).
(3) Raise vehicle on hoist.
(4) Drain engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(5) Remove engine oil drain plug and drain engine
oil.
(6) Lower vehicle.
(7) Remove radiator upper hose.
(8) Remove the cooling fan shroud-to-radiator
mounting bolts.
9 - 238 ENGINE 5.9L DIESELBR/BE
ENGINE 5.9L DIESEL (Continued)

(9) Remove viscous fan/drive assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
Remove the cooling fan and shroud together.
(10) Disconnect the coolant recovery bottle hose
from the radiator filler neck and remove bottle from
fan shroud (Fig. 2).
(11) Disconnect heater core supply and return
hoses from the cylinder head fitting and coolant pipe.
(12) Raise vehicle on hoist.
(13) Remove transmission and transfer case (if
equipped.).
(14) Disconnect exhaust pipe from turbocharger
extension pipe (Fig. 3).
(15) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).
(16) Disconnect A/C suction/discharge hose from
the rear of the A/C compressor.
(17) Lower vehicle.
(18) Disconnect lower radiator hose from radiator
outlet.
(19)Automatic Transmission models:Discon-
nect transmission oil cooler lines from radiator using
special tool #6931.
(20) Remove radiator (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(21) Remove upper radiator support panel.
(22)
Remove front bumper (Refer to 13 - FRAMES &
BUMPERS/BUMPERS/FRONT BUMPER - REMOVAL).
(23) If A/C equipped, disconnect A/C condenser
refrigerant lines.
(24) Disconnect charge air cooler piping.
(25) Remove the two charge air cooler mounting
bolts.
(26) Remove charge air cooler (and A/C condenser
if equipped) from vehicle.
(27) Disconnect engine block heater connector.
(28) Disconnect A/C compressor electrical connec-
tors.
(29) Remove the passenger battery ground cable
from the engine block.
(30) Disconnect power steering pump pressure and
return lines.
(31) Remove accelerator linkage cover.
(32) Leaving all cables attached, remove accelera-
tor pedal position sensor assy. (APPS) (Fig. 4) from
cylinder head bracket and secure out of the way.
(33) Disconnect APPS connector (Fig. 5).
(34) Disconnect vacuum pump supply hose (Fig. 6).
(35) Disconnect the engine harness and ground
cable from the PDC.
(36) Disconnect the fuel supply and return hoses
(Fig. 7).
(37) Remove the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(38) Remove the #5 and #6 cylinder intake and
exhaust rocker arms and pedestals (Fig. 8). Note the
original location for re-assembly.
(39) Loosen but do not remove engine mount
through bolts and nuts.
(40) Attach chain accross engine lift brackets.
(41)
Lift engine up and out of engine compartment.
(42) Install engine to suitable engine stand.
Fig. 2 Coolant Recovery Bottle
1 - T-SLOTS
2 - ALIGNMENT PIN
3 - FAN SHROUD
4 - COOLANT RESERVE/OVERFLOW TANK
Fig. 3 Exhaust Pipe Connection at Turbocharger
1 - EXHAUST PIPE
2 - TURBOCHARGER EXHAUST PIPE
BR/BEENGINE 5.9L DIESEL 9 - 239
ENGINE 5.9L DIESEL (Continued)

REMOVALÐCRANKCASE BREATHER VAPOR
CANISTER
NOTE: It is recommended to empty the contents of
the vapor canister at each oil and filter service
interval.
(1) Loosen cap from top of vapor canister.
(2) Remove nut retaining canister to engine front
cover.
(3) Slide clamp upwards on hose, then remove
hose from crankcase breather.
INSTALLATIONÐENGINE
(1) Install the engine with the cylinder head cover
and the #5 and 6 rocker arm assemblies removed.
(2) Lower the engine into the compartment and
install 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.
(5) Install the #5 and #6 rocker arms and pedes-
tals in their original locations (Fig. 8). Torque the
mounting bolts to 36 N´m (27 ft. lbs.) torque.
(6) Install the cylinder head cover and gasket
(Refer to 9 - ENGINE/CYLINDER HEAD - INSTAL-
LATION).
(7) Connect the fuel supply and return hoses (Fig.
7).
(8) Connect the engine harness connector and
ground cable to the PDC.
(9) Connect the vacuum pump supply hose.(10) Connect the APPS connector (Fig. 5).
(11) Install the APPS assembly bracket to the cyl-
inder head bracket.
(12) Install the throttle linkage cover.
(13) Connect the power steering pressure and
return lines.
(14) Connect the passenger battery ground cable to
the engine block. Tighten the bolt to 77 N´m (57 ft.
lbs.) torque.
(15) Connect the engine block heater connector.
(16) Connect the a/c compressor electrical connec-
tors.
(17) Install the charge air cooler and a/c condenser
(if a/c equipped). Install and tighten the charge air
cooler mounting bolts to 2 N´m (17 in. lbs.) torque.
(18) Connect the charge air cooler piping. Torque
all clamps to 8 N´m (72 in. lbs.) torque.
(19) Connect the a/c refrigerant lines to the a/c
condenser (if equipped).
(20) Install the front bumper (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT
BUMPER - INSTALLATION).
(21) Install the radiator upper support panel.
(22) Install the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION).
Fig. 8 Rocker Arm and PedestalÐRemoval/
Installation
1 - ROCKER ARM
2 - PEDESTALFig. 9 Crankcase Breather Vapor Canister
1 - ENGINE FRONT COVER STUD
2 - STRAP
3 - VAPOR CANISTER
4 - NUT
5 - CAP
6 - CRANKCASE BREATHER
7 - CLAMP
8 - HOSE
BR/BEENGINE 5.9L DIESEL 9 - 241
ENGINE 5.9L DIESEL (Continued)

(23) Connect the transmission quick-connect oil
cooler lines to the radiator. Push together until an
audible ªclickº is heard. Verify connection by pulling
apart.
(24) Raise vehicle.
(25) Connect a/c compressor suction/discharge hose
(if a/c equipped).
(26) Install the radiator lower hose and clamps.
(27) Install the starter motor (Refer to 8 - ELEC-
TRICAL/STARTING/STARTER MOTOR - INSTAL-
LATION).
(28) Install the transmission and transfer case (if
equipped).
(29) Connect the exhaust pipe to the turbocharger
elbow (Fig. 3). Torque the bolts to 34 N´m (25 ft. lbs.)
torque.
(30) Connect the transmission auxiliary oil cooler
lines (if equipped).
(31) Lower the vehicle
(32) Connect the heater core supply and return
hoses.
(33) Install the cooling fan and shroud at the same
time (Refer to 7 - COOLING/ENGINE/RADIATOR
FAN - INSTALLATION).
(34) Install the coolant recovery bottle to the fan
shroud (Fig. 2) and connect the hose to the radiator
filler neck.
(35) Install the windshield washer bottle to the fan
shroud and connect the pump supply hose and elec-
trical connections.
(36) Install the radiator upper hose and clamps.
(37) Change oil filter and install new engine oil.
(38) Fill cooling system with coolant (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(39) Connect battery negative cables.
(40) Perform the fuel line air bleed procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(41) Start engine and inspect for engine oil, cool-
ant, and fuel leaks.
INSTALLATIONÐCRANKCASE BREATHER
VAPOR CANISTER
(1) Position vapor canister with strap over stud on
engine front cover. Install retaining nut. Tighten nut
10 N´m ( 89 in. lbs.).
(2) If removed, position hose onto crankcase
breather, then position clamp.
(3) Position lower portion of hose into vapor canis-
ter, then install and tighten cap.
SPECIFICATIONS
5.9L DIESEL
DESCRIPTION SPECIFICATION
Engine Type In-Line 6 Cyl. Turbo
Diesel
Bore and Stroke 102.0 X 120.0 mm
(4.02 X 4.72 in.)
Displacement 5.9L (359 cu. in.)
Compression Ratio
245 H.P. Version 17.0:1
235 H.P. Version 16.3:1
Horsepower (A/T and 5
Speed M/T)235 @ 2700 rpm
Horsepower (6 Speed M/T
Only)245 @ 2700 rpm
Torque Rating (A/T and 5
Speed M/T)460 ft. lbs. @ 1600 rpm
Torque Rating (6 Speed
M/T Only)505 ft. lbs. @ 1600 rpm
Firing Order 1-5-3-6-2-4
Lubrication System Pressure Feed-Full Flow
With Bypass Valve
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
Connecting Rods Cross Rolled Micro Alloy
PISTONS AND CONNECTING RODS
Piston
Skirt Diameter 101.864 ± 101.88 mm
(4.0104 ± 4.011 in.)
Ring Groove Clearance
Intermediate (Max.) 0.095 mm (0.0037 in.)
Oil Control (Max.) 0.085 mm (0.0033 in.)
Piston Pins
Pin Diameter (Min.) 39.990 mm (1.5744 in.)
Bore Diameter (Max.) 40.025 mm (1.5758 in.)
Piston Ring End Gap
Top Ring 0.35 ± 0.45 mm
9 - 242 ENGINE 5.9L DIESELBR/BE
ENGINE 5.9L DIESEL (Continued)