coolant DODGE RAM 2002 Service Owners Manual

EXCESSIVE WHITE SMOKE
POSSIBLE CAUSE CORRECTION
Engine coolant temperature sensor malfunctioning. A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information. Also check
thermostat operation (Refer to 7 - COOLING/ENGINE/
ENGINE COOLANT THERMOSTAT - DIAGNOSIS AND
TESTING).
Engine Control Module (ECM) not calibrated or has
incorrect calibration.A DTC should have been set. Refer to Powertrain
Diagnostic Procedures Information.
Fuel filter plugged. Perform Fuel Pressure Drop Test (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL TRANSFER PUMP -
DIAGNOSIS AND TESTING).
Fuel grade not correct or fuel quality is poor. Temporarily change fuel brands and note condition.
Change brand if necessary.
Fuel heater element or fuel heater temperature sensor
malfunctioning. This will cause wax type build-up in fuel
filter.Refer to Fuel Heater Testing (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL HEATER -
DIAGNOSIS AND TESTING).
Fuel injector malfunctioning. A DTC should have been set. Perform9Cylinder
Balance Test9using DRB scan tool to isolate individual
cylinders. Also refer to Powertrain Diagnostic
Procedures Information and, (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/FUEL INJECTOR -
DIAGNOSIS AND TESTING).
Fuel injector hold-downs loose. Torque to specifications.
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.
9 - 120 ENGINE 5.9L DIESELBR/BE
ENGINE 5.9L DIESEL (Continued)

STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND 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. 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 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 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.
9 - 122 ENGINE 5.9L DIESELBR/BE

(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.
REMOVAL
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) 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.
Fig. 2 Coolant Recovery Bottle
1 - T-SLOTS
2 - ALIGNMENT PIN
3 - FAN SHROUD
4 - COOLANT RESERVE/OVERFLOW TANK
BR/BEENGINE 5.9L DIESEL 9 - 123
ENGINE 5.9L DIESEL (Continued)

(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).
(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.
Fig. 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
9 - 126 ENGINE 5.9L DIESELBR/BE
ENGINE 5.9L DIESEL (Continued)

CAUTION: Certain engine degreasers or cleaners
may discolor or damage the plastic housing of the
Filter Minder. Cover and tape the Filter Minder if any
engine degreasers or cleaners are to be used.
To test, turn the engine off. If the yellow disc (Fig.
12) has reached the red colored zone on the gradu-
ated scale, the air cleaner element should be
replaced. Refer to the proceeding removal/installation
paragraphs.
Resetting the Filter Minder:After the air
cleaner (filter) element has been replaced, press the
rubber button on the top of the Filter Minder (Fig.
12). This will allow the yellow colored disc to reset.
After the button has been pressed, the yellow disc
should spring back to the UP position.
If the Filter Minder gauge has reached the red col-
ored zone, and after an examination of the air
cleaner (filter) element, the element appears to be
clean, the high reading may be due to a temporary
condition such as snow build-up at the air intake.
Temporary high restrictions may also occur if the air
cleaner (filter) element has gotten wet such as during
a heavy rain or snow. If this occurs, allow the ele-
ment to dry out during normal engine operation.
Reset the rubber button on the top of the Filter
Minder and retest after the element has dried.Removal
(1) Loosen air inlet tube clamp at air cleaner hous-
ing inlet (Fig. 11). Remove this tube at air cleaner
housing cover.
(2) The housing cover is equipped with four (4)
spring clips (Fig. 11) and is hinged at front with plas-
tic tabs. Unlatch clips from top of air cleaner housing
and tilt housing cover up and forward for cover
removal.
(3) Remove air cleaner element from air cleaner
housing.
INSTALLATION
(1) Before installing a new air cleaner element,
clean inside of air cleaner housing.
(2) Position air cleaner cover to tabs on front of air
cleaner housing. Latch four spring clips to seal cover
to housing.
(3) Install air inlet tube at air cleaner housing
inlet. Note hose alignment notches at both inlet hose
and air cleaner cover (Fig. 11).
(4) Position tube clamp to inlet tube and tighten to
3 N´m (25 in. lbs.) torque.
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.
Fig. 12 Filter MinderŸÐDiesel Engine
1 - PRESS BUTTON TO RESET
2 - YELLOW DISC
3 - RED ZONE
4 - TO AIR FILTER HOUSING
5 - FILTER MINDER
9 - 130 ENGINE 5.9L DIESELBR/BE
AIR CLEANER ELEMENT (Continued)

(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.(17) Remove the throttle linkage cover (Fig. 15).
(18) Remove the six (6) accelerator pedal position
sensor assembly-to-cylinder head bracket bolts (Fig.
16) and secure the entire assembly out of the way.
Disconnect the APPS connector (Fig. 17).It is not
necessary to disconnect the cables from the
throttle control assembly.
(19) Remove the intake air grid heater wires from
the grid heater.
(20) Remove engine oil level indicator tube attach-
ing bolt from the air inlet 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
Fig. 15 Throttle Linkage Cover
1 - CABLE/LEVER/LINKAGE COVER
2 - PUSH UP LOWER TAB
3 - SCREWS/CLIPS (2)
4 - TAB PUSH HERE
BR/BEENGINE 5.9L DIESEL 9 - 131
CYLINDER HEAD (Continued)

(b) Install the rear line bundle (cyls. #3, 5, and
6), and tighten the threads at the head and pump
by hand.
(c) Torque the connections at the cylinder head
first. Torque connections to 38 N´m (28 ft. lbs.).
(d) Torque the line connections at the injection
pump to 24 N´m (18 ft. lbs.).
(e) Install the front line bundle (cyls. #1, 2, and
4) following the same procedure used for the rear
line bundle.
(f) Torque the connections at the cylinder head
first. Torque connections to 38 N´m (28 ft. lbs.).
(g) Torque the line connections at the injection
pump to 24 N´m (18 ft. lbs.).
(h) Install the injection line support bracket to
intake cover/cylinder head bolts and torque to 24
N´m (18 ft. lbs.).
(16) Install the engine lift bracket at the rear of
cylinder head. Torque to 77 N´m (57 ft. lbs.).
(17) Install the fuel filter to injection pump low
pressure line. Inspect and replace sealing washers if
necessary. Torque banjo bolts to 24 N´m (18 ft. lbs.).
(18) Using new gaskets, install the intake grid
heater and air inlet housing. Torque bolts to 24 N´m
(18 ft. lbs.).(19) Connect the APPS connector (Fig. 17).
(20) Install the APPS assembly. to the cylinder
head bracket and torque bolts to 12 N´m (105 in.
lbs.).
(21) Install the throttle linkage cover (Fig. 15).
(22) Install the charge air cooler-to-air inlet hous-
ing duct assembly. Torque all clamps to 11 N´m (100
in. lbs.).
(23) Connect intake grid heater wires.
(24) Fasten engine harness to front of cylinder
head with bolt.
(25) Install engine harness ground wire and torque
bolt to 24 N´m (18 ft. lbs.).
(26) Connect engine coolant temperature sensor
connector.
(27) Connect radiator upper hose to thermostat
housing.
(28) Install generator upper bracket and torque
bolts to 41 N´m (31 ft. lbs.).
(29) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(30) Install exhaust manifold/turbocharger assem-
bly. and start all bolts/spacers by hand. Torque bolts
to 43 N´m (32 ft. lbs.).
(31) Connect turbocharger oil drain tube.
(32) Perform the turbocharger pre-lube procedure.
Refer to Group 11, Exhaust System and Turbo-
charger for the correct procedure.
(33) Connect the turbocharger oil supply line.
(34) Install air cleaner housing and duct.
(35) Raise vehicle on hoist.
(36) Install exhaust pipe to turbocharger elbow
(Fig. 14). Torque bolts to 34 N´m (25 ft. lbs.).
(37) Lower vehicle.
(38) Fill engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(39) Start engine and check for leaks.
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.
Fig. 33 Cylinder Head Cover Installation
1 - BOLT (5)
2 - GASKET
3 - ªTOP FRONTº
4 - ISOLATOR (5)
BR/BEENGINE 5.9L DIESEL 9 - 137
CYLINDER HEAD (Continued)

(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.
(2) Remove cylinder head cover (Fig. 47) (Refer to
9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(3) Remove the crankcase breather and vapor can-
ister (Fig. 48).
(4) Using the crankshaft barring tool #7471±B,
rotate the engine and align the pump gear mark with
the top dead center (TDC) mark on the gear housing
cover (Fig. 49).
(5) With the engine in this position (pump gear
mark at 12 o'clock), valve lash can be measured at
the following rocker arms:INTAKE 1±2±4 /
EXHAUST 1±3±5. Measure the valve lash by insert-
ing a feeler gauge between the rocker arm socket and
crosshead (Fig. 50). Refer to VALVE LASH LIMIT
CHART for the correct specifications. If the measure-
ment fallswithinthe limits, adjustment/resettingis
notnecessary. If measurement finds the lashout-
sideof the limits, adjustment/resettingisrequired.
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
Fig. 47 Cylinder Head Cover and Gasket
1 - BOLT (5)
2 - GASKET
3 - ªTOP FRONTº
4 - ISOLATOR (5)
BR/BEENGINE 5.9L DIESEL 9 - 141
INTAKE/EXHAUST VALVES & SEATS (Continued)

Overall variation end to end or side to side is 0.075
mm (0.003 inch).
If the surface exceeds the limit, .
Inspect the cylinder bores for damage or excessive
wear.
Measure the cylinder bores (Fig. 80). If the cylin-
der bores exceeds the limit, (Refer to 9 - ENGINE/
ENGINE BLOCK - STANDARD PROCEDURE).
Inspect the camshaft bores for scoring or excessive
wear.
Measure the camshaft bores (Refer to 9 - ENGINE
- SPECIFICATIONS). Limit for the No.1 bore applies
to the ID of the bushing.
If a bore exceeds the limit, (Refer to 9 - ENGINE/
ENGINE BLOCK/CAMSHAFT & BEARINGS (IN
BLOCK) - STANDARD PROCEDURE).
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)
REMOVAL
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).
Fig. 79 Combustion Deck Face Measurement
1 - STRAIGHT EDGE
2 - FEELER GAUGE
Fig. 80 Cylinder Bore Diameter
Fig. 81 Tappet Bore Diameter
9 - 152 ENGINE 5.9L DIESELBR/BE
ENGINE BLOCK (Continued)

(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).
(14) If A/C equipped, disconnect A/C condenser
refrigerant lines.
(15) Disconnect charge air cooler piping from the
cooler inlet and outlet.
(16) Remove the two charge air cooler mounting
bolts.
(17) Remove charge air cooler (and A/C condenser
if equipped) from vehicle.
(18) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(19) Remove the fan support/hub assembly (Fig.
82).
(20) Remove crankshaft damper (Fig. 83) (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(21) Remove the crankcase breather vapor canister
from the gear housing cover (Fig. 84).
Fig. 82 Fan Support/Hub Removal/Installation
1 - FAN SUPPORT/HUB
2 - FAN PULLEY
Fig. 83 Crankshaft Damper Removal/Installation
1 - DAMPER
2 - BOLT
BR/BEENGINE 5.9L DIESEL 9 - 153
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)