seat adjustment DODGE RAM 2003 Service User Guide

(2) Install the caliper adapter (Fig. 50) (Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
(3) Install the caliper adapter bolts (Fig. 50) and
tighten the mounting bolts to 135 N´m (100 ft.lbs).
(4) Install the disc brake caliper, (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION).
(5) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - STANDARD PROCE-
DURE).
(6) Lower the vehicle.
INSTALLATION - FRONT
(1) On models with all-wheel antilock system
(ABS), check condition of tone wheel on hub/bearing.
If teeth on wheel are damaged, hub/bearing assembly
will have to be replaced (tone wheel is not serviced
separately).
(2) Install the rotor onto the hub/bearing wheel
studs.
(3) Install the caliper adapter assembly,(Refer to 5
- BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION) and tighten
adapter bolts to:
(4) Install the wheel and tire assembly, (Refer to
22 - TIRES/WHEELS/WHEELS - STANDARD PRO-
CEDURE) and lower the vehicle.
(5) Apply the brakes several times to seat brake
pads. Be sure to obtain firm pedal before moving
vehicle.
SUPPORT PLATE
REMOVAL
(1) Remove wheel and tire assembly.
(2) Remove the disc brake caliper (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - REMOVAL).
(3) Remove the caliper adapter (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - REMOVAL).
(4) Remove the rotor (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTORS - REMOVAL).
(5) Remove the axle shaft (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/REAR AXLE - 9 1/4/AXLE
SHAFTS - REMOVAL).
(6) Remove the park brake shoes (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - REMOVAL).
(7) Remove the parking brake cable from the
brake lever.
(8) Remove the bolts attaching the support plate to
the axle and remove the support plate (Fig. 54).
INSTALLATION
(1) Install support plate on axle flange (Fig. 55).
Tighten attaching bolts to 115 N´m (85 ft. lbs.).
(2) Install parking brake cable in the brake lever.
(3) Install the park brake shoes (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - INSTALLA-
TION). (Fig. 55).
(4) Install axle shaft, (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/REAR AXLE - 9 1/4/AXLE
SHAFTS - INSTALLATION).
(5) Adjust brake shoes to drum with brake gauge
(Refer to 5 - BRAKES/PARKING BRAKE/SHOES -
ADJUSTMENTS).
Fig. 52 FRONT ROTOR
1 - ROTOR
2 - HUB/BEARING
Fig. 53 8 LUG ROTOR ASSEMBLY
1 - SPRING
2 - SHOCK
3 - UPPER AND LOWER SUSPENSION ARMS
4 - DISC BRAKE CALIPER
5 - DISC BRAKE CALIPER ADAPTER
6 - ROTOR
DRBRAKES - BASE 5 - 29
ROTORS (Continued)

(6) Remove the cable from the frame bracket.
(7) Remove the cable from the axle bracket.
(8) Remove the cable bracket from the shock
bracket.
(9) Remove the brake cable from the brake lever.
(Fig. 60)
REMOVAL - LEFT REAR CABLE
(1) Raise and support the vehicle.
(2) Lockout the parking brake cable (Fig. 58).
(3) Loosen the brake cable at the equalizer and
adjuster nut.
(4) Remove the left brake cable from the equalizer.
(5) Remove the brake cable from the frame
bracket.
(6) Remove the brake cable from the brake lever.
(Fig. 61)
INSTALLATION
INSTALLATION - FRONT PARKING BRAKE
CABLE
(1) From inside the vehicle, insert the cable end
fitting into the hole in the pedal assembly.
(2) Seat the cable retainer in the pedal assembly.
(3) Engage the cable ball end in clevis on the pedal
assembly.
(4) Route the cable through the floorpan and
install the body grommet.
(5) Place the carpet down and install the left cowl
trim and sill plate.
(6) Raise and support the vehicle.
(7) Route the cable through the underbody bracket
and seat the cable end fitting in the bracket.(8) Connect the cable to the cable connector.
(9) Perform the park brake adjustment procedure,
(Refer to 5 - BRAKES/PARKING BRAKE/CABLE
TENSIONER - ADJUSTMENTS).
(10) Lower the vehicle.
INSTALLATION - REAR PARK BRAKE CABLE
(1) Push each cable end through the brake cable
support plate hole until the cable end fitting tabs
lock into place.
NOTE: Pull on the cable to ensure it is locked into
place.
(2) Push the cable through the frame bracket.
(3) Lock the left cable end fitting tabs into the
frame bracket hole.
(4) Install the rear cables into the tensioner rod
behind the rear of the brake assembly.
(5) Install the cable to the intermediate cable con-
nector.
(6) Release and remove the lock out device.
(7) Perform the park brake adjustment procedure,
(Refer to 5 - BRAKES/PARKING BRAKE/CABLE
TENSIONER - ADJUSTMENTS).
(8) Remove the supports and lower the vehicle.
INSTALLATION - RIGHT REAR CABLE
(1) Install the brake cable to the brake lever. (Fig.
62)
(2) Install the cable bracket to the shock bracket.
(3) Install the cable to the axle bracket.
(4) Install the cable to the frame bracket.
(5) Install the right cable to the equalizer.
Fig. 60 CABLE MOUNT
1 - SUPPORT PLAT
2 - CABLE MOUNT
3 - PARK BRAKE LEVER
4 - CABLE
Fig. 61 REAR DISC BRAKE
1 - DISC BRAKE CALIPER
2 - DISC BRAKE ROTOR
3 - DUST SHIELD
4 - REAR PARKING BRAKE CABLE
5 - DISC BRAKE CALIPER MOUNTING BOLTS
5 - 32 BRAKES - BASEDR
CABLES (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
NOISE
(Objectionable squeal, squeak, or
rumble is heard or felt while drive
belt is in operation)1. Incorrect belt tension 1. Inspect/Replace tensioner if
necessary
2. Bearing noise 2. Locate and repair
3. Belt misalignment 3. Align belt/pulley(s)
4. Belt to pulley mismatch 4. Install correct belt
5. Driven component induced
vibration5. Locate defective driven
component and repair
TENSION SHEETING FABRIC
FAILURE
(Woven fabric on outside,
circumference of belt has cracked or
separated from body of belt)1. Tension sheeting contacting
stationary object1. Correct rubbing condition
2. Excessive heat causing woven
fabric to age2. Replace belt
3. Tension sheeting splice has
fractured3. Replace belt
CORD EDGE FAILURE
(Tensile member exposed at edges
of belt or separated from belt body)1. Incorrect belt tension 1. Inspect/Replace tensioner if
necessary
2. Belt contacting stationary object 2. Replace belt
3. Pulley(s) out of tolerance 3. Replace pulley
4. Insufficient adhesion between
tensile member and rubber matrix4. Replace belt
REMOVAL
CAUTION: DO NOT LET TENSIONER ARM SNAP
BACK TO THE FREEARM POSITION, SEVER DAM-
AGE MAY OCCUR TO THE TENSIONER.
Belt tension is not adjustable. Belt adjustment is
maintained by an automatic (spring load) belt ten-
sioner.
(1) Disconnect negative battery cable from battery.
(2) Rotate belt tensioner until it contacts it's stop.
Remove belt, then slowly rotate the tensioner into
the freearm position. (Fig. 8).
INSTALLATION
Belt tension is not adjustable. Belt adjustment is
maintained by an automatic ( spring load ) belt ten-
sioner.
(1) Check condition of all pulleys.CAUTION: When installing the serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction (Fig. 8).
(2) Install new belt (Fig. 8). Route the belt around
all pulleys except the idler pulley. Rotate the ten-
sioner arm until it contacts it's stop position. Route
the belt around the idler and slowly let the tensioner
rotate into the belt. Make sure the belt is seated onto
all pulleys.
(3) With the drive belt installed, inspect the belt
wear indicator (Fig. 9). On 4.7L Engines only, the gap
between the tang and the housing stop (measure-
ment A) must not exceed 24 mm (.94 inches). If the
measurement exceeds this specification replace the
serpentine accessory drive belt.
DRACCESSORY DRIVE 7 - 27
DRIVE BELTS - 3.7L / 4.7L (Continued)

DRIVER SEAT SWITCH
DESCRIPTION
The power seat on this model can be adjusted in
eight different directions, up, down, front up, front
down, rear up, rear down, rearward and forward.
The power seat switch (Fig. 1) on this model has an
additional switch knob for adjusting the power lum-
bar support. The power seat switch is located on the
outboard side of the seat cushion on the seat cushion
side shield. Refer to the owner's manual in the vehi-
cle glove box for more information on the power seat
switch functions and the seat adjusting procedures.
The individual switches in the power seat switch
assembly cannot be repaired. If one switch is dam-
aged or faulty, the entire power seat switch assembly
must be replaced.
OPERATION
When a power switch control knob or knobs are
actuated, a battery feed and a ground path are
applied through the switch contacts to the power seat
track or recliner adjuster motor. The selected
adjuster motor operates to move the seat track or
recliner through its drive unit in the selected direc-
tion until the switch is released, or until the travel
limit of the adjuster is reached. When the switch ismoved in the opposite direction, the battery feed and
ground path to the motor are reversed through the
switch contacts. This causes the adjuster motor to
run in the opposite direction.
No power seat switch should be held applied in any
direction after the adjuster has reached its travel
limit. The power seat adjuster motors each contain a
self-resetting circuit breaker to protect them from
overload. However, consecutive or frequent resetting
of the circuit breaker must not be allowed to con-
tinue, or the motor may be damaged.
DIAGNOSIS AND TESTING - DRIVER SEAT
SWITCH
For circuit descriptions and diagrams, refer to Wir-
ing.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the power seat switch from the power
seat.
(3) Use an ohmmeter to test the continuity of the
power seat switches in each position. See the Power
Seat Switch Continuity chart (Fig. 2). If OK, refer to
Power Seat Track Diagnosis and Testing in this
group. If not OK, replace the faulty power seat
switch.
DRIVER POWER SEAT SWITCH TEST TABLE
DRIVER SWITCH
POSITIONCONTINUITY BETWEEN
OFF B-N, B-J, B-M
B-E, B-L, B-K
VERTICAL UP A-E, A-M, B-N, B-E
VERTICAL DOWN A-J, A-N, B-M, B-E
Fig. 1 DR Power Seat Switch
1 - POWER SEAT SWITCH ASSEMBLY
2 - FRONT SEAT CUSHION ADJUSTMENT BUTTON
3 - COMPLETE SEAT ADJUSTMENT BUTTON
4 - REAR SEAT CUSHION ADJUSTMENT BUTTON
5 - LUMBAR ADJUSTMENT BUTTON
Fig. 2 Testing Driver Power Seat Switch
DRPOWER SEATS 8N - 15

DRIVER POWER SEAT SWITCH TEST TABLE
DRIVER SWITCH
POSITIONCONTINUITY BETWEEN
HORIZONTAL
FORWARDA-L, B-K
HORIZONTAL
REARWARDA-K, B-L
FRONT TILT UP A-M, B-N
FRONT TILT DOWN A-N, B-M
REAR TILT UP A-E, B-J
REAR TILT DOWN A-J, B-E
LUMBAR OFF O-P, O-R, P-R
LUMPAR UP (INFLATE) O-P, Q-R
LUMBAR DOWN
(DEFLATE)O-R, P-Q
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the seat cushion side shield from the
seat. Refer to the Body section of the service manual
for the procedure.
(3) Pull the switch bezel or side shield unit out
from the seat far enough to access the switch wire
harness connector. Gently pry the locking tabs of the
switch away from the wire harness connector and
carefully unplug the connector from the power seat
switch module.
(4) Remove the screws that secure the power seat
switch (Fig. 3).
INSTALLATION
(1) Position the power seat switch on the seat
cushion side shield and install the screws that secure
the power seat switch to seat cushion side shield.
(2) Connect the electrical connector.
(3) Install the seat cushion side shield on the seat.
Refer to the Body section of the service manual for
the procedure.
(4) If equipped, install the screw that secures the
recliner lever to the recliner mechanism release shaft
on the outboard side of the front seat.
(5) Connect the battery negative cable.
PASSENGER SEAT SWITCH
DESCRIPTION
The power seat on this model can be adjusted in
eight different directions, up, down, front up, front
down, rear up, rear down, rearward and forward.
The power seat switch (Fig. 4) on this model has an
additional switch knob for adjusting the power lum-
bar support. The power seat switch is located on the
outboard side of the seat cushion on the seat cushion
side shield. Refer to the owner's manual in the vehi-
cle glove box for more information on the power seat
switch functions and the seat adjusting procedures.
Fig. 3 Power Seat Switch Remove/Install
1 - SEAT SIDE SHIELD
2 - POWER SEAT SWITCH
3 - SCREWS
Fig. 4 DR Power Seat Switch
1 - POWER SEAT SWITCH ASSEMBLY
2 - FRONT SEAT CUSHION ADJUSTMENT BUTTON
3 - COMPLETE SEAT ADJUSTMENT BUTTON
4 - REAR SEAT CUSHION ADJUSTMENT BUTTON
5 - LUMBAR ADJUSTMENT BUTTON
8N - 16 POWER SEATSDR
DRIVER SEAT SWITCH (Continued)

(4) Remove the screws that secure the power seat
switch (Fig. 6).
INSTALLATION
(1) Position the power seat switch on the seat
cushion side shield and install the screws that secure
the power seat switch to seat cushion side shield.
(2) Connect the electrical connector.
(3) Install the seat cushion side shield on the seat.
Refer to the Body section of the service manual for
the procedure.
(4) If equipped, install the screw that secures the
recliner lever to the recliner mechanism release shaft
on the outboard side of the front seat.
(5) Connect the battery negative cable.
POWER SEAT TRACK
DESCRIPTION
The eight-way power seat option includes a power
seat track assembly located under each front seat
(Fig. 7). The power seat track assembly replaces the
standard manually operated seat tracks. The lower
half of the power seat track is secured at the front
with two bolts to the floor panel seat cross member,
and at the rear with two bolts to the floor panel.
Four nuts secure the bottom of the seat cushion
frame to the upper half of the power seat track unit.
The power seat track assembly cannot be repaired,
and is serviced only as a complete assembly. If any
component in this assembly is faulty or damaged, the
entire power seat track must be replaced.
OPERATION
The power seat track unit includes three reversible
electric motors that are secured to the upper half of
the track unit. Each motor moves the seat adjuster
through a combination of worm-drive gearboxes and
screw-type drive units.
The front and rear of the seat are operated by two
separate vertical adjustment motors. These motors
can be operated independently of each other, tilting
the entire seat assembly forward or rearward; or,
they can be operated in unison by selecting the
proper power seat switch functions, which will raise
or lower the entire seat assembly. The third motor is
the horizontal adjustment motor, which moves the
seat track in the forward and rearward directions.
DIAGNOSIS AND TESTING - POWER SEAT
TRACK
For complete power seat circuit descriptions and
diagrams, refer to Wiring Diagrams.
Operate the power seat switch to move all three
seat motors in each direction. The seat should move
in each of the selected directions. If the power seat
track fails to operate in only one direction, move the
seat track a short distance in the opposite direction
and test again to be certain that the track is not at
its travel limit. If the power seat track still fails to
operate in only one direction, refer to Diagnosis and
Testing of the Power Seat Switch in this section. If
Fig. 6 Power Seat Switch Remove/Install
1 - SEAT SIDE SHIELD
2 - POWER SEAT SWITCH
3 - SCREWS
Fig. 7 DR Driver Power Seat Track
1 - POWER SEAT TRACK ASSEMBLY
2 - SEAT TRACK WIRE HARNESS
3 - SEAT BELT BUCKLE ASSEMBLIES
8N - 18 POWER SEATSDR
PASSENGER SEAT SWITCH (Continued)

adjustments. Refer to Specifications Section to obtain
specified height and allowable tensions. Replace any
springs that do not meet specifications (Fig. 19).
INSTALLATION
(1) coat the valve stem with clean engine oil and
insert it into the cylinder head.
(2) Install the valve stem seal. make sure the seal
is fully seated and that the garter spring at the top
of the seal is intact.
(3) Install the spring and the spring retainer (Fig.
20).
(4) Using the valve spring compressor, compress
the spring and install the two valve spring retainer
halves.
(5) Release the valve spring compressor and make
sure the two spring retainer halves and the spring
retainer are fully seated.
(6) lubricate the camshaft journal with clean
engine oil then Position the camshaft (with the
sprocket dowel on the left camshaft at 11 o'clock and
the right camshaft at 12 o'clock), then position the
camshaft bearing caps.
(7) Install the camshaft bearing cap retaining
bolts. Tighten the bolts 9±13 N´m (100 in. lbs.) in
1¤2
turn increments in the sequence shown (Fig. 21).
(8) Position the hydraulic lash adjusters and
rocker arms(Refer to 9 - ENGINE/CYLINDER
HEAD/ROCKER ARM / ADJUSTER ASSY - INSTAL-
LATION).
Fig. 19 Testing Valve Springs
1 - SPECIAL TOOL C-647
Fig. 20 Valve Assembly Configuration
1 - VALVE LOCKS (3±BEAD)
2 - RETAINER
3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
Fig. 21 Camshaft Bearing Caps Tightening
Sequence
DRENGINE - 3.7L 9 - 29
INTAKE/EXHAUST VALVES & SEATS (Continued)

NOTE: It may be necessary to tap the top of the
valve spring to loosen the spring retainers locks
enough to be removed.
(4) Remove the two spring retainer lock halves.
NOTE: the valve spring is under tension use care
when releasing the valve spring compressor.
(5) Remove the valve spring compressor.
(6) Remove the spring retainer, and the spring.
NOTE: Check for sharp edges on the keeper
grooves. Remove any burrs from the valve stem
before removing the valve from the cylinder head.
(7) Remove the valve from the cylinder head.
NOTE: The valve stem seals are common between
intake and exhaust.
(8) Remove the valve stem seal. Mark the valve for
proper installation.
TESTING VALVE SPRINGS
NOTE: Whenever the valves are removed from the
cylinder head it is recommended that the valve
springs be inspected and tested for reuse.
Inspect the valve springs for physical signs of wear
or damage. Turn table of tool C-647 until surface is
in line with the 40.12 mm (1.579 in.) mark on the
threaded stud and the zero mark on the front. Place
spring over the stud on the table and lift compress-
ing lever to set tone device. Pull on torque wrench
until Ping is heard. Take reading on torque wrench
at this instant. Multiply this reading by two. This
will give the spring load at test length. Fractional
measurements are indicated on the table for finer
adjustments. Refer to Specifications Section to obtain
specified height and allowable tensions. Replace any
springs that do not meet specifications (Fig. 42).
INSTALLATION
(1) coat the valve stem with clean engine oil and
insert it into the cylinder head.
(2) Install the valve stem seal. make sure the seal
is fully seated and that the garter spring at the top
of the seal is intact.
(3) Install the spring and the spring retainer (Fig.
43).
(4) Using the valve spring compressor, compress
the spring and install the two valve spring retainer
halves.
(5) Release the valve spring compressor and make
sure the two spring retainer halves and the spring
retainer are fully seated.(6) lubricate the camshaft journal with clean
engine oil then Position the camshaft (with the
sprocket dowel on the left camshaft at 11 o'clock and
the right camshaft at 12 o'clock), then position the
camshaft bearing caps.
Fig. 42 Testing Valve Springs
1 - SPECIAL TOOL C-647
Fig. 43 Valve Assembly Configuration
1 - VALVE LOCKS (3±BEAD)
2 - RETAINER
3 - VALVE STEM OIL SEAL
4 - INTAKE VALVE
5 - EXHAUST VALVE
6 - VALVE SPRING
DRENGINE - 4.7L 9 - 123
INTAKE/EXHAUST VALVES & SEATS (Continued)

ing stones. A true and complete surface must be
obtained.
(2) Measure the concentricity of valve seat using a
dial indicator. Total runout should not exceed 0.051
mm (0.002 in.) total indicator reading.
(3) Inspect the valve seat with Prussian blue, to
determine where the valve contacts the seat. To do
this, coat valve seat LIGHTLY with Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is trans-
ferred to the top edge of valve face, lower valve seat
with a 15É stone. If the blue is transferred to bottom
edge of valve face raise valve seat with a 60É stone.
(4) When seat is properly positioned the width of
intake seats should be 1.016-1.524 mm (0.040-0.060
in.). The width of the exhaust seats should be 1.524-
2.032 mm (0.060-0.080 in.).
VALVE SPRINGS
Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested. As an example the compression length of
the spring to be tested is 1-5/16 in.. Turn table of
Universal Valve Spring Tester Tool until surface is in
line with the 1-5/16 in. mark on the threaded stud.
Be sure the zero mark is to the front (Fig. 15). Place
spring over stud on the table and lift compressing
lever to set tone device. Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by 2. This will give the
spring load at test length. Fractional measurements
are indicated on the table for finer adjustments.
Refer to specifications to obtain specified height and
allowable tensions. Discard the springs that do not
meet specifications.
REMOVAL
(1) Remove the cylinder head (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(2) Compress valve springs using Valve Spring
Compressor Tool MD- 998772A and adapter 6716A.
(3) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(4) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
valve guides. Identify valves to ensure installation in
original location.
CLEANING
Clean valves thoroughly. Discard burned, warped,
or cracked valves.
Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner.
INSPECTION
Measure valve stems for wear. If wear exceeds
0.051 mm (0.002 in.), replace the valve.
Measure valve stem guide clearance as follows:
(1) Install Valve Guide Sleeve Tool C-3973 over
valve stem and install valve (Fig. 16). The special
sleeve places the valve at the correct height for
checking with a dial indicator.
(2) Attach dial indicator Tool C-3339 to cylinder
head and set it at right angles to valve stem being
measured (Fig. 17).
(3) Move valve to and from the indicator. The total
dial indicator reading should not exceed 0.432 mm
(0.017 in.). Ream the guides for valves with oversize
stems if dial indicator reading is excessive or if the
stems are scuffed or scored.
INSTALLATION
(1) Clean valves thoroughly. Discard burned,
warped and cracked valves.
(2) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.Fig. 15 Testing Valve Spring for Compressed
Length
1 - TORQUE WRENCH
2 - VALVE SPRING TESTER
Fig. 16 Positioning Valve with Tool C-3973
1 - VALVE
2 - SPACER TOOL
9 - 248 ENGINE - 5.9LDR
INTAKE/EXHAUST VALVES & SEATS (Continued)

ENGINE 5.9L DIESEL
TABLE OF CONTENTS
page page
ENGINE 5.9L DIESEL
DESCRIPTION........................282
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐENGINE
DIAGNOSIS - MECHANICAL............283
DIAGNOSIS AND TESTINGÐSMOKE
DIAGNOSIS CHARTS.................285
DIAGNOSIS AND TESTINGÐCYLINDER
COMPRESSION/LEAKAGE TESTS.......288
STANDARD PROCEDURE
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS........289
STANDARD PROCEDURE - REPAIR
DAMAGED OR WORN THREADS........289
STANDARD PROCEDUREÐHYDROSTATIC
LOCK..............................290
REMOVAL
REMOVALÐENGINE..................290
REMOVALÐCRANKCASE BREATHER....291
INSTALLATION
INSTALLATIONÐENGINE..............291
INSTALLATIONÐCRANKCASE BREATHER . 292
SPECIFICATIONS
5.9L DIESEL........................293
TORQUE...........................294
SPECIAL TOOLS
5.9L DIESEL ENGINE.................294
ENGINE DATA PLATE
DESCRIPTION........................297
AIR CLEANER ELEMENT
REMOVAL............................297
INSTALLATION........................298
CYLINDER HEAD
DESCRIPTION........................298
REMOVAL............................298
CLEANING
CLEANINGÐCYLINDER HEAD..........300
CLEANINGÐCROSSHEADS............300
CLEANINGÐPUSHRODS..............301
INSPECTION
INSPECTION - CYLINDER HEAD.........301
INSPECTIONÐCROSSHEADS..........301
INSPECTIONÐPUSHRODS.............302
INSTALLATION........................302
CYLINDER HEAD COVER(S)
REMOVAL
REMOVALÐCYLINDER HEAD COVER....304
REMOVALÐROCKER HOUSING.........304
CLEANING...........................304INSPECTION.........................304
INSTALLATION
INSTALLATIONÐCYLINDER HEAD COVER . 304
INSTALLATIONÐROCKER HOUSING.....304
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION........................305
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVES,
GUIDES AND SPRINGS................305
STANDARD PROCEDURE - VALVE LASH
ADJUSTMENT AND VERIFICATION.......308
REMOVAL - VALVE SPRINGS AND SEALS . . . 308
INSTALLATION........................309
ROCKER ARM / ADJUSTER ASSY
DESCRIPTION........................310
REMOVAL............................310
CLEANING...........................310
INSPECTION..........................311
INSTALLATION........................312
ENGINE BLOCK
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER
BLOCK REFACING...................312
STANDARD PROCEDURE - CYLINDER
BORE - DE-GLAZE...................313
STANDARD PROCEDUREÐCYLINDER
BORE REPAIR.......................313
STANDARD PROCEDUREÐCAM BORE
REPAIR ............................315
INSPECTION.........................316
CAMSHAFT & BEARINGS (IN BLOCK)
REMOVAL
REMOVALÐCAMSHAFT BEARINGS......317
REMOVAL - CAMSHAFT...............317
INSPECTION.........................318
INSTALLATION
INSTALLATION - CAMSHAFT BEARINGS . . 320
INSTALLATION - CAMSHAFT............320
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - CONNECTING
ROD BEARING AND CRANKSHAFT
JOURNAL CLEARANCE................321
CRANKSHAFT AND GEAR
DESCRIPTION........................322
REMOVALÐGEAR.....................322
INSTALLATION - GEAR..................322
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - MAIN BEARING
CLEARANCE........................322
9 - 280 ENGINE 5.9L DIESELDR