battery DODGE RAM 2001 Service Repair Manual

CYLINDER HEAD
DESCRIPTION
The cylinder head (Fig. 13) is constructed of cast
iron and is a one piece cross flow design with four
valves per cylinder. The arrangement of two intake
and two exhaust valves per cylinder allows for a cen-
trally 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 hardened 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 (Fig. 14).
(5) Lower vehicle.
(6) Remove air cleaner housing and snorkel from
the vehicle. Cap off turbocharger air inlet to prevent
intrusion of dirt or foreign material.
(7) Disconnect cab heater core supply and return
hoses from the cylinder head and heater pipe.
(8) Disconnect turbocharger oil drain tube at rub-
ber hose connection. Cap off open ports to prevent
intrusion of dirt or foreign material.
(9) Disconnect turbocharger oil supply line at the
turbocharger end. Cap off open ports to prevent
intrusion of dirt or foreign material.
(10) Remove exhaust manifold-to-cylinder head
bolts and spacers. Remove exhaust manifold and tur-
bocharger from the vehicle as an assembly.
(11) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(12) Remove generator upper bracket.
(13) Disconnect radiator upper hose from the ther-
mostat housing.
(14) Disconnect the coolant temperature sensor
connector.
(15) Remove the engine harness to cylinder head
attaching bolt at front of head.
(16) Remove the engine harness ground fastener
at front of head below the thermostat housing.
Fig. 13 Cylinder Head and Gasket
1 - THERMOSTAT BORE
2 - INTAKE RUNNER
3 - CYLINDER HEAD
4 - CYLINDER HEAD GASKET
5 - CYLINDER BLOCK
Fig. 14 Exhaust Pipe-to-Turbocharger Elbow
1 - EXHAUST PIPE
2 - TURBOCHARGER EXHAUST PIPE
9 - 246 ENGINE 5.9L DIESELBR/BE

CYLINDER HEAD COVER(S)
REMOVAL
(1) Disconnect both battery negative cables.
(2) Loosen the five (5) cylinder head cover bolts
(Fig. 34). Remove the front three bolts and leave the
rear two bolts in the cover.
(3) Lift cover off of cylinder head.
CLEANING
Using a suitable solvent, Clean and dry gasket
mating surfaces on cylinder head and cover. Wipe
gasket dry and inspect for re-use.
INSPECTION
The cylinder head cover gasket and isolators
are reusable.However, should cracks be present in
the rubber/silicone construction, the defective compo-
nents should be replaced.
INSTALLATION
(1) Install the gasket as shown in (Fig. 34). Make
sure the gasket is properly located around the cylin-
der head bolts, with the words ªtop frontº facing up
and towards front of engine.(2) Place two bolts and isolators into the rear two
mounting holes and install the cover.
(3) Install the remaining bolts and isolators. Start-
ing with the center bolt, torque in a circular pattern
to 24 N´m (18 ft. lbs.).
(4) Connect both battery negative cables.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The valves are made of heat resistant steel, and
have chrome plated stems to prevent scuffing. The
intake and exhaust valves are both similar in head
diameter and overall length, but they have unique
face angles which makes them non-interchangeable.
The valves are distinguished by unique dimples on
the exhaust valve head (Fig. 35).
The exhaust valve springs are made from high
strength, chrome silicon steel. The exhaust valve
springs are also exhaust brake compatible.
STANDARD PROCEDURE-VALVES,GUIDES AND
SPRINGS
REMOVAL
(1) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(2) Support cylinder head on stands, or install
head bolts upside down (through combustion surface
side) to protect injector tips from damage from work
bench.
(3) Remove the injector clamp (Fig. 36) from the
cylinder(s) to be serviced.Do not remove the bolt
shown in (Fig. 36).
Fig. 34 Cylinder Head Cover and Gasket
1 - BOLT (5)
2 - GASKET
3 - ªTOP FRONTº
4 - ISOLATOR (5)
Fig. 35 Valve Identification
1 - INTAKE VALVES
2 - EXHAUST VALVES
BR/BEENGINE 5.9L DIESEL 9 - 253

Measure the valve spring free length and maxi-
mum inclination (Fig. 44).
Test valve spring force with tool C-647 (Fig. 45).
INSTALLATION
(1) Install new valve seals. The yellow springs are
for the intake valves and the green seals are for the
exhaust valves.(2) Install the valves in their original postion. The
exhaust valves are identified by a dimple on the
valve head (Fig. 46).
(3) Install the valve springs and retainer.
(4) Install the valve spring compressor tool 8319±A
as shown in (Fig. 37) and (Fig. 38).
(5) Compress the valve springs and install the
valve retaining locks (Fig. 39).
(6) Remove the compressor and repeat the proce-
dure on the remaining cylinders.
(7) Install the injector clamp and hold down bolts
and tighten to 10 N´m (89 in. lbs.) torque.
(8) Install the cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
STANDARD PROCEDUREÐVALVE LASH
ADJUSTMENT AND VERIFICATION
NOTE: To obtain accurate readings, valve lash mea-
surements AND adjustments should only be per-
formed when the engine coolant temperature is less
than 60É C (140É F).
The 24±valve overhead system is a ªlow-mainte-
nanceº design. Routine adjustments are no longer
necessary, however, measurement should still take
place when trouble-shooting performance problems,
or upon completion of a repair that includes removal
and installation of the valve train components.
(1) Disconnect battery negative cables.
Fig. 44 Measure Valve Spring Free Length and Max.
Inclination
VALVE SPRING FREE LENGTH
47.75 mm (1.88 in.)
MAX INCLINATION
1.5 mm (.059 in.)
Fig. 45 Testing Valve Spring with Tool C-647
1 - SPECIAL TOOL C-647
VALVE SPRING FORCE 35.33 mm @ 339.8 N (1.39 IN. @76.4
lbs.)
Fig. 46 Valve Identification
1 - INTAKE VALVES
2 - EXHAUST VALVES
9 - 256 ENGINE 5.9L DIESELBR/BE
INTAKE/EXHAUST VALVES & SEATS (Continued)

(6) If adjustment/resetting is required, loosen the
lock nut on rocker arms and turn the adjusting screw
until the desired lash is obtained:
²INTAKE0.254 mm (0.010 in.)
²EXHAUST0.508 mm (0.020 in.)Tighten the lock
nut and re-check the valve lash.
(7) Using the crankshaft barring tool, rotate the
crankshaftone revolution (360É) to align the pump
gear mark to the 6 o'clock position in relation to the
TDC mark on the gear housing cover (Fig. 49).(8) With the engine in this position (pump gear
mark at 6 o'clock), 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 determin-
ing whether adjustment is necessary, and adjust
those that are found to be outside of the limits.
(9) Install the cylinder head cover (Fig. 47) (Refer
to 9 - ENGINE/CYLINDER HEAD/CYLINDER
HEAD COVER(S) - INSTALLATION).
(10) Install the fuel pump gear access cover.
(11) Connect the battery negative cables.
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove the cylinder head cover (Fig. 52) (Refer
to 9 - ENGINE/CYLINDER HEAD/CYLINDER
HEAD COVER(S) - REMOVAL).
(3) Remove the rocker arms and crossheads (Fig.
53) from the cylinder(s) to be serviced. Mark each
component so they can be installed in their original
position.
(4) Remove the crankcase breather vapor canister
and breather housing (Fig. 55).
(5) Using the crankshaft barring tool #7471±B
(Fig. 51), rotate the engine to line up the mark on
the pump gear with the TDC mark on the cover.At
this engine position, cylinders #1 and #6 can be
serviced.
(6) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) With the fuel injection pump gear mark aligned
at TDC, 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.
(8) 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.
Fig. 49 Fuel Pump Gear Timing Mark Orientation
1 - MEASURE/ADJUST INTAKE 1, 2, 4 EXHAUST 1, 3, 5
2 - MEASURE/ADJUST INTAKE 3, 5, 6 EXHAUST 2, 4, 6
Fig. 50 Measuring Valve Lash
1 - INTAKE
2 - FEELER GAUGE
3 - EXHAUST
9 - 258 ENGINE 5.9L DIESELBR/BE
INTAKE/EXHAUST VALVES & SEATS (Continued)

(4)Verify valve lash adjustment (Refer to 9 -
ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
(5) Install cylinder head cover and reusable gasket
(Fig. 52) (Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - INSTALLATION).
(6) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(7) Connect battery negative cables.
ROCKER ARM / ADJUSTER
ASSY
DESCRIPTION
The 24±valve overhead system incorporates rocker
arms that are designed to allow fuel injector service
without removing the rocker arms and pedestals. The
unique intake and exhaust rocker arms have their
own rocker shafts and are lubricated by passages
intersecting the cylinder block main oil rifle. Cross-
heads are used (Fig. 58), which allow each rocker
arm to operate two valves.
The solid push rods are hardened at the rocker
arm and tappet contact areas for superior strength
and durability.
REMOVAL
(1) Disconnect the battery negative cables.
(2) Remove cylinder head cover (Fig. 59) (Refer to
9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(3) Remove the rocker arm/pedestal fasteners (Fig.
60) and remove rocker arm and pedestal from cylin-
der head. Mark the arms and pedestals so they can
be installed in their original position.
CAUTION: When removing the rocker arms, the
sockets (Fig. 61) may come loose and fall into the
engine. Make sure they stay with the arm upon
removal/installation.
(4) Lift the push rod(s) up and out of the engine
(Fig. 62). Mark them so they can be installed in their
original position.
NOTE: The #5 cyl. exhaust and #6 cyl. intake and
exhaust push rods must be raised through the pro-
vided cowl panel access holes.
(5) Lift the crosshead(s) off of the valve stems.
Mark them so they can be installed in their original
position.
Fig. 58 Overhead System Components
1 - EXHAUST ROCKER ARM
2 - INTAKE ROCKER ARM
3 - ROCKER SHAFT
4 - SOCKET
5 - ADJUSTING SCREW LOCK NUT
6 - PUSH ROD
7 - PEDESTAL
8 - CROSSHEAD
Fig. 59 Cylinder Head CoverÐRemoval/Installation
1 - BOLT (5)
2 - GASKET
3 - ªTOP FRONTº
4 - ISOLATOR (5)
BR/BEENGINE 5.9L DIESEL 9 - 261
INTAKE/EXHAUST VALVES & SEATS (Continued)

Push Rods
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. 65).
Roll the push rod on a flat work surface with the
socket end hanging off the edge (Fig. 66). Replace
any push rod that appears to be bent.
Crossheads
Inspect the crossheads for cracks and/or excessive
wear on rocker lever and valve tip mating surfaces
(Fig. 67).
INSTALLATION
(1) If previously removed, install the push rods in
their original location.Verify that they are seated
in the tappets.
(2) Lubricate the valve tips and install the cross-
heads in their original locations.
(3) Lubricate the crossheads and push rod sockets
and install the rocker arms and pedestals (Fig. 60) intheir original locations. Tighten bolts to 36 N´m (27
ft. lbs.) torque.
(4)Verify valve lash adjustment (Refer to 9 -
ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
(5) Install cylinder head cover and reusable gasket
(Fig. 59) (Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - INSTALLATION).
(6) Connect battery negative cables.
ENGINE BLOCK
STANDARD PROCEDURE-CYLINDER BLOCK
REFACING
(1) The combustion deck can be refaced twice. The
first reface should be 0.25 mm (0.0098 inch). If addi-
tional refacing is required, an additional 0.25 mm
(0.0098 inch) can be removed. Total allowed refacing
is 0.50 mm (0.0197 inch) - (Fig. 68).
Fig. 64 Measuring Rocker Arm Shaft
ROCKER ARM SHAFT (MIN.)
21.965 mm (.865 in.)
Fig. 65 Inspecting Push Rod for Cracks
Fig. 66 Inspecting Push Rod for Flatness
Fig. 67 Inspecting Crosshead for Cracks
BR/BEENGINE 5.9L DIESEL 9 - 263
ROCKER ARM / ADJUSTER ASSY (Continued)

Inspect the tappet bores for scoring or excessive
wear 16.000 mm min - 16.055 mm max ( .63 in. min
- .6321 in. max ) (Fig. 81). If out of limits, replace the
cylinder block.
CAMSHAFT & BEARINGS (IN
BLOCK)
REMOVALÐCAMSHAFT BEARINGS
NOTE: Measure the diameter of each bore. (The
limit for the bushing in the No.1 bore is the same as
for the other bores without bushings). The limit of
the inside diameter is 54.089 min. - 54.164 max. mm
(2.1295 min. - 2.1325 max. inch). If the camshaft
bore for the first cam bushing is worn beyond the
limit, install a new service bushing. Inspect the rest
of the camshaft bores for damage or excessive
wear.If the bores without a bushing are worn
beyond the limit, the engine must be removed for
machining and installation of service bushings. If
badly worn, replace the cylinder block.
(1) Remove the camshaft (Refer to 9 - ENGINE/
ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - REMOVAL).
(2) Remove the bushing from the No.1 bore, using
a universal cam bushing tool.
(3) Mark the cylinder block so you can align the oil
hole in the cylinder block with the oil hole in the
bushing.
REMOVALÐCAMSHAFT
(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 into container suitable for
re-use (Refer to 7 - COOLING - STANDARD PROCE-
DURE).
(5) Lower vehicle.
(6) Remove radiator upper hose.
(7) Remove viscous fan/drive assembly and fan
shroud (Refer to 7 - COOLING/ENGINE/RADIATOR
FAN - REMOVAL).
(8) Disconnect the coolant recovery bottle hose
from the radiator filler neck.
(9) Disconnect lower radiator hose from radiator
outlet.
(10)Automatic Transmission models:Discon-
nect transmission oil cooler lines from radiator using
Special Tool 6931 (unless equipped with finger-re-
lease disconnect).
(11) Remove radiator mounting screws and lift
radiator out of engine compartment.
(12) Remove upper radiator support panel.
(13) Remove front bumper assembly (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT
BUMPER - REMOVAL).
Fig. 79 Combustion Deck Face Measurement
1 - STRAIGHT EDGE
2 - FEELER GAUGE
Fig. 80 Cylinder Bore Diameter
Fig. 81 Tappet Bore Diameter
9 - 268 ENGINE 5.9L DIESELBR/BE
ENGINE BLOCK (Continued)

(10)Verify valve lash adjustment (Refer to 9 -
ENGINE/CYLINDER HEAD/INTAKE/EXHAUST
VALVES & SEATS - STANDARD PROCEDURE).
(11)
Install the cylinder head cover and reusable gas-
ket (Fig. 85) (Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - INSTALLATION).
(12) Install gear housing cover (Refer to 9 -
ENGINE/VALVE TIMING/GEAR HOUSING COVER
- INSTALLATION).
(13) Install the crankshaft damper (Fig. 83) (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
(14) Install the fan support/hub assembly (Fig. 82)
and tighten bolts to 24 N´m (18 ft. lbs.) torque.
(15) Install the crankcase breather housing (Refer
to 9 - ENGINE - INSTALLATION).
(16) Install the charge air cooler (with a/c con-
denser and auxiliary transmission oil cooler, if
equipped) and tighten the mounting bolts to 2 N´m
(17 in. lbs.) torque.
(17) Connect charge air cooler inlet and outlet
pipes. Tighten clamps to 10 N´m (100 in. lbs.) torque.
(18) Install the radiator upper support panel.
(19) Close radiator petcock and lower the radiator
into the engine compartment. Tighten the mounting
bolts to 11 N´m (95 in. lbs.) torque.
(20) Raise vehicle on hoist.
(21)
Connect radiator lower hose and install clamp.
(22) Connect transmission auxiliary oil cooler lines
(if equipped).
(23) Lower vehicle.
(24) Install the fan shroud and tighten the mount-
ing screws to 6 N´m (50 in. lbs.) torque.(25) Install the viscous fan/drive assembly (Refer
to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
(26) Install the coolant recovery and windshield
washer fluid reservoirs to the fan shroud.
(27) Connect the coolant recovery hose to the radi-
ator filler neck.
(28) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(29) Install the front bumper assembly (Refer to 13
- FRAMES & BUMPERS/BUMPERS/FRONT
BUMPER - INSTALLATION).
(30) Add engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(31) Charge A/C system with refrigerant (if A/C
equipped) (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE).
(32) Connect the battery negative cables.
(33) Start engine and check for engine oil and cool-
ant leaks.
CONNECTING ROD BEARINGS
STANDARD PROCEDUREÐCONNECTING ROD
BEARING AND CRANKSHAFT JOURNAL
CLEARANCE
Measure the connecting rod bore with the bearings
installed and the bolts tightened to 100 N´m (73 ft.
lbs.) torque.
Record the smaller diameter.
Measure the diameter of the rod journal at the
location shown (Fig. 99). Calculate the average diam-
eter for each side of the journal.
The clearance is the difference between the con-
necting rod bore (smallest diameter) and the average
diameter for each side of the crankshaft journal.
CONNECTING ROD JOURNAL DIAMETER
LIMITS CHART
DESCRIPTION MEASUREMENT
CRANKSHAFT ROD
JOURNAL DIAMETERMINIMUM 68.962 mm
(2.715 in.)
MAXIMUM 69.013 mm
(2.717 in.)
OUT-OF-ROUND MAXIMUM 0.050 mm
(0.002 in.)
TAPER MAXIMUM 0.013 mm
(0.0005 in.)
BEARING CLEARANCE MAXIMUM 0.089 mm
(0.0035 in.)
Fig. 98 Camshaft Backlash and End Clearance
1 - CAMSHAFT GEAR
2 - CAMSHAFT GEAR BACKLASH
3 - CAMSHAFT GEAR CLEARANCE
BACKLASH Ð 0.152Ð0.33 mm
(0.006Ð0.013 inch)
CLEARANCE Ð 0.1Ð0.46 mm
(0.004Ð0.0182 inch)
9 - 274 ENGINE 5.9L DIESELBR/BE
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

CRANKSHAFT MAIN JOURNAL DIAMETER
CHART
ITEM SPECIFICATION
MINIMUM DIAMETER 82.962 mm (3.2662 in.)
MAXIMUM DIAMETER 83.013 mm (3.2682 in.)
Calculate the main bearing journal to bearing
clearance. the clearance specifications are 0.119 mm
(0.00475 inch). If the crankshaft journal is within
limits, replace the main bearings. If not within spec-
ifications, grind the crankshaft to next size and use
oversize bearings.
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.The fan
drive nut has left handed threads.(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 (Fig. 103).
(13) Raise the vehicle on hoist.
(14) Remove the crankshaft damper (Fig. 104).
(15) Remove the gear cover-to-housing bolts and
gently pry the cover away from the housing, taking
care not to mar the gasket surfaces.
(16) Support the cover on a flat work surface with
wooden blocks (Fig. 105), and using a suitable punch
and hammer, drive the old seal out of the cover from
the outside of the cover (Fig. 105).
Fig. 102 Crankshaft Main Journal Diameter
Fig. 103 Fan Support Hub AssemblyÐRemoval/
Installation
1 - FAN SUPPORT/HUB
2 - FAN PULLEY
Fig. 104 Crankshaft DamperÐRemoval/Installation
1 - DAMPER
2 - BOLT
9 - 276 ENGINE 5.9L DIESELBR/BE
CRANKSHAFT MAIN BEARINGS (Continued)

INSTALLATION
(1)Clean cover and housing gasket mating surfaces.
Use a suitable scraper and be careful not to damage the
gear housing surface, since it is aluminum. 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. 106). Strike the driver handle until the installation
tool bottoms out on the inside of the cover.
(5) Install the plastic seal pilot (provided with seal
kit) into the crankshaft seal.
(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.
107).
(8) Install the cover bolts and tighten to 24 N´m
(18 ft. lbs.) torque. Remove pilot tool.
(9) Install the crankshaft damper (Fig. 104) and
torque the bolts to 125 N´m (92 ft. lbs.). Use theengine barring tool to keep the engine from rotating
during tightening operation.
(10) Install the fan support/hub assembly (Fig.
103) and torque bolts to 24 N´m (18 ft. lbs.).
(11) Install cooling fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION).
(12) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(13) Refill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(14) Connect battery negative cables.
(15) Start engine and check for oil leaks.
Fig. 105 Removing Seal from Cover
1 - PUNCHFig. 106 Installing Seal Into Cover With Tool 8281
1 - SEAL INSTALLER 8281
2 - DRIVER HANDLE C4171
3 - SEAL
Fig. 107 Installing Front Cover with Seal Pilot
1 - SEAL PILOT
BR/BEENGINE 5.9L DIESEL 9 - 277
CRANKSHAFT OIL SEAL - FRONT (Continued)