timing belt DODGE RAM 2003 Service Workshop Manual

(11) Remove the rear oil seal retainer(Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT REAR
OIL SEAL RETAINE - REMOVAL).
(12) Remove and discard the crankshaft rear oil
seal.
(13) Remove and discard the front crankshaft oil
seal.
INSTALLATION
(1) Select the proper main bearings(Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT MAIN
BEARINGS - STANDARD PROCEDURE).
(2) Install main bearings in block and caps, and
lubricate bearings.
(3) Position the crankshaft into the cylinder block.
(4) Install the thrust washers.
NOTE: The main cap crossbolts are torqued after
final torque of the main cap bolts. Always use a
new washer/seal on crossbolts.
(5) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately
tighten in two steps using the following sequence
(Fig. 8).
²Step1±27N´m(20ft. lbs.) torque.
²Step2±Turnmain cap bolts an additional 90É.
(6) Install the crossbolts with new washer/gasket.
Starting with crossbolt A (Fig. 8) torque each cross-
bolt to 28 N´m torque.
(7) Repeat crossbolt torque procedure.(8) Measure crankshaft end play(Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT MAIN
BEARINGS - STANDARD PROCEDURE).
(9) Position the connecting rods onto the crank-
shaft and install the rod bearing caps(Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON & CONNECT-
ING ROD - INSTALLATION).
(10) Install timing drive(Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION).
(11) Install oil pump and pickup(Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - INSTALLA-
TION).
(12) Install the timing chain cover(Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(13) Install the oil pan(Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
(14) Install the rear main seal and retainer.
(15) Install the vibration damper.
(16) Install the engine(Refer to 9 - ENGINE -
INSTALLATION).
CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE - CRANKSHAFT MAIN
BEARING - FITTING
MAIN BEARING JOURNAL DIAMETER
(CRANKSHAFT REMOVED)
Crankshaft removed from the cylinder block.
Clean the oil off the main bearing journal.
Determine the maximum diameter of the journal
with a micrometer. Measure at two locations 90É
apart at each end of the journal.
The maximum allowable taper is 0.008mm (0.0004
inch.) and maximum out of round is 0.005mm (0.0002
inch). Compare the measured diameter with the jour-
nal diameter specification (Main Bearing Fitting
Chart). Select inserts required to obtain the specified
bearing-to-journal clearance.
CRANKSHAFT MAIN BEARING SELECTION
The main bearings are ªselect fitº to achieve proper
oil clearances. For main bearing selection, the crank-
shaft counterweight has grade identification marks
stamped into it. These marks are read from left to
right, corresponding with journal number 1, 2, 3, 4
and 5.
NOTE: Service main bearings are coded. These
codes identify what size (grade) the bearing is.
Fig. 8 MAINCAP TIGHTENING SEQUENCE
1 - Stud Location
9 - 202 ENGINE - 5.7LDR
CRANKSHAFT (Continued)

INSTALLATION
(1) Throughly clean all gasket resdue from the
engine block.
(2) Use extream care and clean all gasket resdue
from the retainer.
(3) Position the gasket onto the retainer.
(4) Position the retainer onto the engine block.
(5) Install the retainer mounting bolts. Tighten the
bolts to 15 N´m (132 in. lbs.) using a crisscross pat-
tern, starting with the bolt on the lower right.
(6) Install a new rear seal(Refer to 9 - ENGINE/
ENGINE BLOCK/CRANKSHAFT OIL SEAL - REAR
- INSTALLATION).
(7) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
(8) Install the drive plate / flywheel.
(9) Install the transmission.
(10) Check and verify engine oil level.
(11) Start engine and check for leaks.
FLEX PLATE
REMOVAL
(1) Remove the transmission.
(2) Remove the bolts and flexplate.
INSTALLATION
(1) Position the flexplate onto the crankshaft and
install the bolts hand tight.
(2) Tighten the flexplate retaining bolts to 95 N´m
(70 ft. lbs.).
(3) Install the transmission.
PISTON & CONNECTING ROD
DESCRIPTION
CAUTION: Do not use a metal stamp to mark con-
necting rods as damage may result, instead use ink
or a scratch awl.
The pistons are made of a high strength aluminum
alloy. Piston skirts are coated with a solid lubricant
(Molykote) to reduce friction and provide scuff resis-
tance. The piston top ring groove and land is anod-
ized. The connecting rods are made of forged
powdered metal, with a ªfractured capº design. A
pressed fit piston pin is used to attach the piston and
connecting rod.
STANDARD PROCEDUREÐPISTON FITTING
(1) To correctly select the proper size piston, a cyl-
inder bore gauge, capable of reading in 0.003 mm (.0001 in.) INCREMENTS is required. If a bore gauge
is not available, do not use an inside micrometer.
(2) Measure the inside diameter of the cylinder
bore at a point 38.0 mm (1.5 inches) below top of
bore. Start perpendicular (across or at 90 degrees) to
the axis of the crankshaft at point A and then take
an additional bore reading 90 degrees to that at point
B (Fig. 11).
(3) The coated pistons will be serviced with the
piston pin and connecting rod pre-assembled.
(4) The coating material is applied to the piston
after the final piston machining process. Measuring
the outside diameter of a coated piston will not pro-
vide accurate results (Fig. 10). Therefore measuring
the inside diameter of the cylinder bore with a dial
Bore Gauge isMANDATORY. To correctly select the
proper size piston, a cylinder bore gauge capable of
reading in 0.003 mm (.0001 in.) increments is
required.
(5) Piston installation into the cylinder bore
requires slightly more pressure than that required
for non-coated pistons. The bonded coating on the
piston will give the appearance of a line-to-line fit
with the cylinder bore.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the following components:
²Oil pan and gasket/windage tray (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - REMOVAL).
²Cylinder head covers (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
REMOVAL) and (Refer to 9 - ENGINE/CYLINDER
HEAD/CYLINDER HEAD COVER(S) - REMOVAL).
²Timing chain cover (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- REMOVAL).
Fig. 10 Moly Coated Piston
1 - MOLY COATED
2 - MOLY COATED
DRENGINE - 5.7L 9 - 205
CRANKSHAFT REAR OIL SEAL RETAINER (Continued)

OIL PUMP
REMOVAL
(1) Remove the oil pan and pick-up tube(Refer to 9
- ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(2) Remove the timing chain cover(Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(3) Remove the four bolts, and the oil pump.
CLEANING
(1) Wash all parts in a suitable solvent.
INSPECTION
CAUTION: Oil pump pressure relief valve and
spring should not be removed from the oil pump. If
these components are disassembled and or
removed from the pump the entire oil pump assem-
bly must be replaced.
(1) Remove the pump cover.
(2) Clean all parts thoroughly. Mating surface of
the oil pump housing should be smooth. If the pump
cover is scratched or grooved the oil pump assembly
should be replaced.
(3) Slide outer rotor into the body of the oil pump.
Press the outer rotor to one side of the oil pump body
and measure clearance between the outer rotor and
the body (Fig. 28). If the measurement is 0.235mm
(0.009 in.) or more the oil pump assembly must be
replaced.
(4) Install the inner rotor in the into the oil pump
body. Measure the clearance between the inner and
outer rotors (Fig. 29). If the clearance between the
rotors is .150 mm (0.006 in.) or more the oil pump
assembly must be replaced.
(5) Place a straight edge across the body of the oil
pump (between the bolt holes), if a feeler gauge of
.095 mm (0.0038 in.) or greater can be inserted
between the straightedge and the rotors, the pump
must be replaced (Fig. 30).
(6) Reinstall the pump cover. Torque fasteners to
15 N´m (132 in. lbs.).
NOTE: The 5.7 Oil pump is released as an assem-
bly. There are no DaimlerChrysler part numbers for
Sub-Assembly components. In the event the oil
pump is not functioning or out of specification it
must be replaced as an assembly.
Fig. 28 Measuring Outer Rotor Clearance
1 - FEELER GAUGE
2 - OUTER ROTOR
Fig. 29 Measuring Clearance Between Rotors -
Typical
1 - OUTER ROTOR
2 - FEELER GAUGE
3 - INNER ROTOR
9 - 218 ENGINE - 5.7LDR

INSTALLATION
(1) Position the oil pump onto the crankshaft and
install the 4 oil pump retaining bolts.
(2) Tighten the oil pump retaining bolts to 28 N´m
(250 in. lbs.).
(3) Install the timing chain cover(Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(4) Install the pick-up tube and oil pan(Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
INTAKE MANIFOLD
DESCRIPTION
The intake manifold is made of a composite mate-
rial and features long runners which maximizes low
end torque. The intake manifold uses single plane
sealing which consist of eight individual press in
place port gaskets to prevent leaks.
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKAGE
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.(2) Spray a small stream of water at the suspected
leak area.
(3) If a change in RPM is observed the area of the
suspected leak has been found.
(4) Repair as required.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove resonator assembly and air inlet hose.
(3) Disconnect electrical connectors for the follow-
ing components:
²Manifold Absolute Pressure (MAP) Sensor
²Intake Air Temperature (IAT) Sensor
²Throttle Position (TPS) Sensor
²Coolant Temperature (CTS) Sensor
(4) Disconnect brake booster hose and positive
crankcase ventilation (PCV) hose.
(5) Remove generator and set aside.
NOTE: It is not necessary to remove lines or
remove freon from A/C compressor.
(6) Remove air conditioning compressor and set
aside..
(7) Bleed fuel system (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY - STANDARD PROCE-
DURE).
(8) Remove intake manifold retaining fasteners in
a crisscross pattern starting from the outside bolts
and ending at the middle bolts.
(9) Remove intake manifold and IAFM as an
assembly.
CLEANING
NOTE: There is NO approved repair procedure for
the intake manifold. If severe damage is found dur-
ing inspection, the intake manifold must be
replaced.
Before installing the intake manifold thoroughly
clean the mating surfaces. Use a suitable cleaning
solvent, then air dry.
INSPECTION
(1) Inspect the intake sealing surface for cracks,
nicks and distortion.
(2) Inspect the intake manifold vacuum hose fit-
tings for looseness or blockage.
(3) Inspect the manifold to throttle body mating
surface for cracks, nicks and distortion.
INSTALLATION
(1) Install intake manifold seals.
(2) Position intake manifold and IAFM.
(3) Install intake manifold retaining bolts, and
tighten in sequence from the middle bolts towards
Fig. 30 Measuring Clearance Over Rotors - Typical
1 - STRAIGHT EDGE
2 - FEELER GAUGE
DRENGINE - 5.7L 9 - 219
OIL PUMP (Continued)

the outside in a crisscross pattern. Torque fasteners
to 12 N´m (105 in. lbs.).
(4) Connect electrical connectors for the following
components:
²Manifold Absolute Pressure (MAP) Sensor
²Intake Air Temperature (IAT) Sensor
²Throttle Position (TPS) Sensor
²Coolant Temperature (CTS) Sensor
²Idle Air Control (IAC) Motor
(5) Install generator.
(6) Install A/C compressor.
(7) Connect Brake booster hose and Positive crank-
case ventilation (PCV) hose.
(8) Install resonator assembly and air inlet hose.
(9) Connect negative cable to battery.
EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifolds are log style with a pat-
ented flow enhancing design to maximize perfor-
mance. The exhaust manifolds are made of high
silicon molybdenum cast iron. A perforated core
graphite exhaust manifold gasket is used to improve
sealing to the cylinder head. The exhaust manifolds
are covered by a three layer laminated heat shield
for thermal protection and noise reduction. The heat
shields are fastened with a torque prevailing nut
that is backed off slightly to allow for the thermal
expansion of the exhaust manifold.
OPERATION
The exhaust manifolds collect the engine exhaust
exiting the combustion chambers, then channels the
exhaust gases to the exhaust pipes attached to the
manifolds.
REMOVAL
EXHAUST MANIFOLD
(1) Disconnect negative battery cable.
(2) Raise vehicle.
(3) Remove exhaust pipe to manifold bolts.
(4) Lower vehicle.
(5) Install engine support fixture special tool
#8534.
(6) Raise engine enough to remove manifolds.
CAUTION: Do not damage engine harness while
raising the engine.
(7) Remove heat shield.
(8) Remove manifold bolts.
(9) Remove manifold and gasket.
CLEANING
Clean mating surfaces on cylinder head and mani-
fold. Wash with solvent and blow dry with com-
pressed air.
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straight edge. Gasket surfaces must be flat
within 0.2 mm per 300 mm (0.008 inch per foot).
INSTALLATION
EXHAUST MANIFOLD
(1) Install manifold gasket and manifold.
(2) Install manifold bolts and tighten to 25 N´m
(18 ft. lbs.).
(3) Install heat shield and tighten nuts to 15 N´m
(11 ft. lbs.).
(4) Lower engine.
CAUTION: Do not damage engine harness while
lowering the engine.
(5) Remove engine support fixture from engine.
(6) Raise vehicle.
(7) Tighten right and left side engine mount
through bolts.
(8) Install exhaust flange to pipe bolts.
(9) Lower vehicle.
(10) Connect negative battery cable.
TIMING/CHAIN COVER
REMOVAL
(1) Disconnect the battery negative cable.
(2) Remove air cleaner assembly.
(3) Drain cooling system.
(4) Remove accessory drive belt.
(5) Remove fan and fan drive assembly (Refer to 7
- COOLING/ENGINE/FAN DRIVE VISCOUS
CLUTCH - REMOVAL).
(6) Remove coolant bottle and washer bottle.
(7) Remove fan shroud.
NOTE: It is not necessary to disconnect A/C lines or
discharge freon.
(8) Remove A/C compressor and set aside.
(9) Remove the generator.
(10) Remove upper radiator hose.
(11) Disconnect both heater hoses at timing cover.
(12) Disconnect lower radiator hose at engine.
(13) Remove accessory drive belt tensioner and
both idler pulleys.
9 - 220 ENGINE - 5.7LDR
INTAKE MANIFOLD (Continued)

(14) Remove crankshaft damper(Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
NOTE: Do not remove the hoses from the power
steering pump.
(15) Remove power steering pump and set aside.
(16) Remove the dipstick support bolt.
(17) Drain the engine oil.
(18) Remove the oil pan and pick up tube(Refer to
9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL).
NOTE: It is not necessary to remove water pump for
timing cover removal.
(19) Remove timing cover bolts and remove cover.
INSTALLATION
(1) Clean timing chain cover and block surface.
NOTE: Always install a new gasket on timing cover.
(2) Install cover and new gasket. Tighten fasteners
to 28 N´m (250 in. lbs.).
NOTE: The large lifting stud is torqued to 55 N´m
(40 ft. lbs.).
(3) Install the oil pan and pick up tube(Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
(4) Install the A/C compressor.
(5) Install the generator.
(6) Install power steering pump.
(7) Install the dipstick support bolt.
(8) Install the thermostat housing.
(9) Install crankshaft damper(Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(10) Install accessory drive belt tensioner assembly
and both idler pulleys.
(11) Install radiator lower hose.
(12) Install both heater hoses.
(13) Install radiator fan shroud.
(14) Install the fan and fan drive assembly
(15) Install the accessory drive belt.
(16) Install the coolant bottle and washer bottle.
(17) Install the upper radiator hose.
(18) Install the air cleaner assembly.
(19) Fill cooling system.
(20) Refill engine oil.
(21) Connect the battery negative cable.
TIMING/CHAIN AND
SPROCKETS
REMOVAL
(1) Disconnect battery negative cable.
(2) Drain cooling system.
(3) Remove Timing Chain Cover.
CAUTION: The camshaft pin and the slot in the cam
sprocket must be clocked at 12:00. The crankshaft
keyway must be clocked at 2:00. The crankshaft
sprocket must be installed so that the dots and or
paint marking is at 6:00.
(4) Re-install the vibration damper bolt finger
tight. Using a suitable socket and breaker bar, rotate
the crankshaft to align timing chain sprockets and
keyways as shown (Fig. 31).
(5) Retract tensioner shoe until hole in shoe lines
up with hole in bracket. Slide a suitable pin into the
holes.
(6) Remove camshaft sprocket attaching bolt and
remove timing chain with crankshaft and camshaft
sprockets.
(7) If tensioner assembly is to be replaced, remove
the tensioner to block bolts and remove tensioner
assembly.
Fig. 31 5.7L TIMING MARK ALIGNMENT
1 - Chain Tensioner
2 - Camshaft Sprocket
3 - Crankshaft Sprocket
DRENGINE - 5.7L 9 - 221
TIMING/CHAIN COVER (Continued)

INSTALLATION
(1) If tensioner assembly is being replaced, install
tensioner and mounting bolts. Torque bolts to 28 N´m
(250 in. lbs.).
(2) Retract tensioner if required.
CAUTION: The camshaft pin and the slot in the cam
sprocket must be clocked at 12:00. The crankshaft
keyway must be clocked at 2:00. The crankshaft
sprocket must be installed so that the dots and or
paint marking is at 6:00.
(3) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores (Fig. 32).
CAUTION: The timing chain must be installed with
the single plated link aligned with the dot and or
paint marking on the camshaft sprocket. The crank-
shaft sprocket is aligned with the dot and or paint
marking on the sprocket between two plated timing
chain links.
(4) Place timing chain around both sprockets (Fig.
32).
(5) Lift sprockets and chain (keep sprockets tight
against the chain in position as shown).(6) Slide both sprockets evenly over their respec-
tive shafts and check alignment of timing marks.
(7) Install the camshaft bolt. Tighten the bolt to
122 N´m (90 ft. lbs.) torque.
(8)Remove tensioner pin.Again, verify align-
ment of timing marks.
(9) Install the oil pump(Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(10) Install the oil pan and pick up(Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
(11) Install the timing chain cover(Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(12) Fill cooling system(Refer to 7 - COOLING -
STANDARD PROCEDURE).
(13) Connect battery negative cable.
(14) Start engine and check for oil and coolant
leaks.
TIMING CHAIN/TENSIONER
DESCRIPTION
The timing chain tensioner is a stamped steel con-
stant tension mechanical design. It is mounted to the
front of the engine, behind the timing chain drive.
OPERATION
The timing chain tension is maintained by routing
the timing chain through the tensioner assembly. A
nylon covered spring steel arm presses on the timing
chain maintaining the correct chain tension.
Fig. 32 5.7L TIMING MARK ALIGNMENT
1 - Chain Tensioner
2 - Camshaft Sprocket
3 - Crankshaft Sprocket
9 - 222 ENGINE - 5.7LDR
TIMING/CHAIN AND SPROCKETS (Continued)

HYDRAULIC LIFTERS
DIAGNOSIS AND TESTINGÐHYDRAULIC
TAPPETS...........................258
REMOVAL............................259
CLEANING...........................260
INSTALLATION........................260
PISTON & CONNECTING ROD
DESCRIPTION........................260
STANDARD PROCEDURE - PISTON FITTING . 260
REMOVAL............................261
CLEANING...........................261
INSPECTION.........................261
INSTALLATION........................261
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING............................262
VIBRATION DAMPER
REMOVAL............................263
INSTALLATION........................263
FRONT MOUNT
REMOVAL............................264
INSTALLATION........................265
REAR MOUNT
REMOVAL............................266
INSTALLATION........................267
LUBRICATION
DESCRIPTION........................267
OPERATION..........................267
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTINGÐENGINE OIL
LEAKS.............................269
DIAGNOSIS AND TESTINGÐENGINE OIL
PRESSURE.........................269
OIL
STANDARD PROCEDURE - ENGINE OIL....269
OIL FILTER
REMOVAL............................270INSTALLATION........................270
OIL PAN
REMOVAL............................270
CLEANING...........................270
INSPECTION.........................271
INSTALLATION........................271
OIL PUMP
REMOVAL............................272
DISASSEMBLY........................272
INSPECTION.........................272
ASSEMBLY...........................274
INSTALLATION........................274
INTAKE MANIFOLD
DESCRIPTION........................274
OPERATION..........................274
DIAGNOSIS AND TESTINGÐINTAKE
MANIFOLD LEAKAGE.................274
REMOVAL............................275
CLEANING...........................275
INSPECTION.........................275
INSTALLATION........................275
EXHAUST MANIFOLD
DESCRIPTION........................277
OPERATION..........................277
REMOVAL............................277
CLEANING...........................277
INSPECTION.........................277
INSTALLATION........................277
TIMING BELT / CHAIN COVER(S)
REMOVAL............................278
INSTALLATION........................278
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL............................279
INSPECTIONÐMEASURING TIMING CHAIN
STRETCH..........................279
INSTALLATION........................279
ENGINE - 5.9L
DESCRIPTION
The 5.9 Liter (360 CID) eight-cylinder engine is a
V-Type lightweight, single cam, overhead valve
engine with hydraulic roller tappets. This engine is
designed for unleaded fuel.
The engine lubrication system consists of a rotor
type oil pump and a full flow oil filter.
The cylinders are numbered from front to rear; 1,
3, 5, 7 on the left bank and 2, 4, 6, 8 on the right
bank. The firing order is 1-8-4-3-6-5-7-2 (Fig. 1).
Fig. 1 Firing Order
9 - 224 ENGINE - 5.9LDR

DIAGNOSIS AND TESTINGÐENGINE DIAGNOSIS - PERFORMANCE
PERFORMANCE DIAGNOSIS CHARTÐGASOLINE ENGINES
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WILL NOT CRANK 1. Weak or dead battery 1. Charge/Replace Battery. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/
BATTERY - STANDARD PROCEDURE).
Check charging system. (Refer to 8 -
ELECTRICAL/CHARGING - DIAGNOSIS
AND TESTING).
2. Corroded or loose battery connections 2. Clean/tighten suspect battery/starter
connections
3. Faulty starter or related circuit(s) 3. Check starting system. (Refer to 8 -
ELECTRICAL/STARTING - DIAGNOSIS
AND TESTING)
4. Seized accessory drive component 4. Remove accessory drive belt and
attempt to start engine. If engine starts,
repair/replace seized component.
5. Engine internal mechanical failure or
hydro-static lock5. Refer to (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
ENGINE CRANKS BUT
WILL NOT START1. No spark 1. Check for spark. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL -
DESCRIPTION)
2. No fuel 2. Perform fuel pressure test, and if
necessary, inspect fuel injector(s) and
driver circuits. (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/FUEL PUMP -
DIAGNOSIS AND TESTING).
3. Low or no engine compression 3. Perform cylinder compression pressure
test. (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING).
ENGINE LOSS OF POWER 1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn distributor shaft 2. Remove and repair distributor (Refer to
8 - ELECTRICAL/IGNITION CONTROL/
DISTRIBUTOR - REMOVAL).
3. Worn or incorrect gapped spark plugs 3. Clean plugs and set gap. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL/
SPARK PLUG - CLEANING).
4. Dirt or water in fuel system 4. Clean system and replace fuel filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression 8. Test cylinder compression (Refer to 9 -
ENGINE - DIAGNOSIS AND TESTING).
9. Burned, warped, or pitted valves 9. Install/Reface valves as necessary
10. Plugged or restricted exhaust system 10. Install new parts as necessary
11. Faulty ignition cables 11. Replace any cracked or shorted cables
9 - 226 ENGINE - 5.9LDR
ENGINE - 5.9L (Continued)

(1) Remove oil pressure sending unit from back of
block.
(2) Insert a 3.175 mm (1/8 in.) finish wire, or
equivalent, into passage.
(3) Plug should be 190.0 to 195.2 mm (7-1/2 to
7-11/16 in.) from machined surface of block (Fig. 19).
If plug is too high, use a suitable flat dowel to posi-
tion properly.
(4) If plug is too low, remove oil pan and No. 4
main bearing cap. Use suitable flat dowel to position
properly. Coat outside diameter of plug with Mopart
Stud and Bearing Mount Adhesive. Plug should be
54.0 to 57.7 mm (2-1/8 to 2-5/16 in.) from bottom of
the block.CAMSHAFT & BEARINGS (IN
BLOCK)
REMOVALÐCAMSHAFT
NOTE: The camshaft has an integral oil pump and
distributor drive gear (Fig. 20).
(1) Remove the radiator (Refer to 7 - COOLING/
ENGINE/RADIATOR - REMOVAL).
(2) Remove the A/C Condenser (if equipped)
(3) Remove the engine cover.
(4) Remove intake manifold (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - REMOVAL).
(5) Remove cylinder head covers (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(6) Remove timing case cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL) and timing chain (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL).
(7) Remove rocker arms.
(8) Remove push rods and tappets. Identify each
part so it can be installed in its original location.
(9) Remove distributor and lift out the oil pump
and distributor drive shaft.
(10) Remove camshaft thrust plate, note location of
oil tab (Fig. 21).
(11) Install a long bolt into front of camshaft to aid
in removal of the camshaft. Remove camshaft, being
careful not to damage cam bearings with the cam
lobes.
INSTALLATIONÐCAMSHAFT
(1) Lubricate camshaft lobes and camshaft bearing
journals and insert the camshaft to within 51 mm (2
inches) of its final position in cylinder block.
(2) Install Camshaft Holder Tool C-3509 with
tongue back of distributor drive gear (Fig. 22).
Fig. 19 Oil Line Plug
1 - RIGHT OIL GALLERY
2 - CYLINDER BLOCK
3 - OIL FROM FILTER TO SYSTEM
4 - OIL TO FILTER
5 - FROM OIL PUMP
6 - CRANKSHAFT
7 - PLUG
Fig. 20 Camshaft and Sprocket Assembly
1 - THRUST PLATE
2 - OIL PUMP AND DISTRIBUTOR DRIVE GEAR INTEGRAL WITH
CAMSHAFT
3 - CAMSHAFT SPROCKET
9 - 250 ENGINE - 5.9LDR
ENGINE BLOCK (Continued)