wheel size DODGE RAM 2003 Service Repair Manual

INTRODUCTION
TABLE OF CONTENTS
page page
VEHICLE SAFETY CERTIFICATION LABEL
DESCRIPTION..........................1
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION..........................2
VEHICLE EMISSION CONTROL INFORMATION
(VECI)
DESCRIPTION..........................3
BODY CODE PLATE
DESCRIPTION..........................4
INTERNATIONAL VEHICLE CONTROL &
DISPLAY SYMBOLS
DESCRIPTION - INTERNATIONAL SYMBOLS . . . 6FASTENER IDENTIFICATION
DESCRIPTION..........................6
FASTENER USAGE
DESCRIPTION - FASTENER USAGE.........9
THREADED HOLE REPAIR
DESCRIPTION - THREADED HOLE REPAIR....9
METRIC SYSTEM
DESCRIPTION..........................9
TORQUE REFERENCES
DESCRIPTION.........................11
VEHICLE SAFETY
CERTIFICATION LABEL
DESCRIPTION
A vehicle safety certification label (Fig. 1) is
attached to every DaimlerChrysler Corporation vehi-
cle. The label certifies that the vehicle conforms to all
applicable Federal Motor Vehicle Safety Standards.
The label also lists:
²Month and year of vehicle manufacture.
²Gross Vehicle Weight Rating (GVWR). The gross
front and rear axle weight ratings (GAWR's) are
based on a minimum rim size and maximum cold tire
inflation pressure.
²Vehicle Identification Number (VIN).
²Type of vehicle.
²Type of rear wheels.
²Bar code.
²Month, Day and Hour (MDH) of final assembly.
²Paint and Trim codes.
²Country of origin.
The label is located on the driver-side door shut-
face.
Fig. 1 VEHICLE SAFETY CERTIFICATION LABEL -
TYPICAL
DRINTRODUCTION 1

OPERATION
²CASTERis the forward or rearward tilt of the
steering knuckle from vertical. Tilting the top of the
knuckle forward provides less positive caster. Tilting
the top of the knuckle rearward provides more posi-
tive caster. Positive caster promotes directional sta-
bility. This angle enables the front wheels to return
to a straight ahead position after turns (Fig. 1)
²CAMBERis the inward or outward tilt of the
wheel relative to the center of the vehicle. Tilting the
top of the wheel inward provides negative camber.
Tilting the top of the wheel outward provides positive
camber. Incorrect camber will cause wear on the
inside or outside edge of the tire (Fig. 1)
²TOEis the difference between the leading inside
edges and trailing inside edges of the front tires.
Wheel toe position out of specification cause's unsta-
ble steering, uneven tire wear and steering wheel off-
center. The wheel toe position is thefinalfront
wheel alignment adjustment (Fig. 1)
²THRUST ANGLEis the angle of the rear axle
relative to the centerline of the vehicle. Incorrect
thrust angle can cause off-center steering and exces-sive tire wear. This angle is not adjustable, damaged
component(s) must be replaced to correct the thrust
angle (Fig. 1)
DIAGNOSIS AND TESTING - PRE-ALIGNMENT
INSPECTION
Before starting wheel alignment, the following
inspection and necessary corrections must be com-
pleted. Refer to Suspension and Steering System
Diagnosis Chart below for additional information.
(1) Inspect tires for size, air pressure and tread
wear.
(2) Inspect front wheel bearings for wear.
(3) Inspect front wheels for excessive radial or lat-
eral runout and balance.
(4) Inspect ball studs, linkage pivot points and
steering gear for looseness, roughness or binding.
(5) Inspect suspension components for wear and
noise.
(6) On 4x4 vehicles check suspension height (LD
only).
(7) Road test the vehicle.
SUSPENSION AND STEERING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
FRONT END NOISE 1. Loose or worn wheel bearing. 1. Replace wheel bearing.
2. Loose or worn steering or
suspension components.2. Tighten or replace components as
necessary.
3. Loose or worn steering or
suspension components.3. Tighten or replace components as
necessary.
EXCESSIVE PLAY IN
STEERING1. Loose or worn wheel bearing. 1. Replace wheel bearing.
2. Loose or worn steering or
suspension components.2. Tighten or replace components as
necessary.
3. Loose or worn steering gear. 3. Replace steering gear.
FRONT WHEELS SHIMMY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.
2. Loose or worn steering or
suspension components.2. Tighten or replace components as
necessary.
3. Tires worn or out of balance. 3. Replace or balance tires.
4. Alignment. 4. Align vehicle to specifications.
VEHICLE INSTABILITY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.
2. Loose or worn steering or
suspension components.2. Tighten or replace components as
necessary.
3. Tire pressure. 3. Adjust tire pressure.
4. Alignment. 4. Align vehicle to specifications.
2 - 2 WHEEL ALIGNMENTDR
WHEEL ALIGNMENT (Continued)

(14) Check fluid level in clutch master cylinder.
CLUTCH HOUSING
DIAGNOSIS AND TESTING
The clutch housing maintains alignment between
the crankshaft and transmission input shaft. Mis-
alignment can cause clutch noise, hard shifting,
incomplete release and chatter. Also premature pilot
bearing, cover release fingers and clutch disc wear.
In severe cases, it can cause premature wear of the
transmission input shaft and front bearing.
NOTE: Only the NV4500 clutch housing can be
checked using the following bore and face runout
procedures. The NV5600 clutch housing is a inte-
gral part of the transmission and can only be
checked off the vehicle.
CLUTCH HOUSING BORE RUNOUT
CAUTION: On diesel engines if housing bore runout
exceeds 0.015 inch, the clutch housing/transmis-
sion adapter plate must be replaced. On gas
engines if housing bore runout exceeds 0.053 in.
the clutch housing must be replaced.
NOTE: Offset dowels are available for gas engines
to correct housing bore runout. They are not avail-
able for diesel engines.
(1) Remove the clutch housing.
(2) Remove the clutch cover and disc.(3) Replace one of the flywheel bolts with an
appropriate size threaded rod that is 10 in. (25.4 cm)
long (Fig. 8). The rod will be used to mount the dial
indicator.
(4) Remove release fork from the clutch housing.
(5) Install clutch housing. Tighten the housing
bolts nearest the alignment dowels first.
(6) Mount dial indicator on the threaded rod and
position indicator plunger on the clutch housing bore
(Fig. 9).
(7) Rotate crankshaft until indicator plunger is at
the topof the housing bore. Zero the indicator at this
point.
(8) Rotate crankshaft and record indicator read-
ings at eight points (45É apart) around the bore (Fig.
10). Take measurement at least twice for accuracy.
Fig. 7 FORK, BEARING AND SPRING CLIPS
1 - FORK
2 - SPRING CLIP
3 - BEARING
4 - SPRING CLIPFig. 8 DIAL INDICATOR MOUNTING STUD
1 - 7/16 - 20 THREAD
2 - NUT
3 - STUD OR THREADED ROD
4 - 10 INCHES LONG
Fig. 9 CLUTCH HOUSING BORE RUNOUT
1 - MOUNTING STUD OR ROD
2 - DIAL INDICATOR
3 - INDICATOR PLUNGER
4 - CLUTCH HOUSING BORE
6 - 8 CLUTCHDR
CLUTCH DISC (Continued)

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SEAT BELT TENSIONER,
SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE SYSTEM CAPACITOR TO DISCHARGE BEFORE
PERFORMING FURTHER DIAGNOSIS OR SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
CLUSTER BULB
This procedure applies to each of the incandescent
cluster illumination lamp bulb and bulb holder units.
If the vehicle is equipped with the optional Remote
Keyless Entry (RKE) system, and the RKE receiver
module was removed from the instrument cluster
rear cover to access the lower center cluster illumi-
nation lamp, reinstall the RKE module after the bulb
is replaced on the circuit board. (Refer to 8 - ELEC-
TRICAL/POWER LOCKS/REMOTE KEYLESS
ENTRY MODULE - INSTALLATION).
CAUTION: Always use the correct bulb size and
type for replacement. An incorrect bulb size or type
may overheat and cause damage to the instrument
cluster, the electronic circuit board and/or the
gauges.
(1) Insert the bulb and bulb holder unit straight
into the correct bulb mounting hole in the cluster
electronic circuit board (Fig. 6).
(2) With the bulb holder fully seated against the
cluster electronic circuit board, turn the bulb holder
clockwise about sixty degrees to lock it into place.
(3) Reinstall the instrument cluster onto the
instrument panel. (Refer to 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - INSTALLATION).
(4) Reconnect the battery negative cable.CLUSTER LENS, HOOD, AND MASK
(1) Position the cluster lens, hood, and mask unit
over the face of the instrument cluster (Fig. 7). Be
certain that the odometer/trip odometer switch but-
ton is inserted through the proper clearance holes in
the mask and the lens.
(2) From the back of the instrument cluster, install
and tighten the eight screws around the outer perim-
eter of the rear cover that secure the lens, hood, and
mask unit to the cluster housing. Tighten the screws
to 1 N´m (10 in. lbs.).
(3) Reinstall the instrument cluster onto the
instrument panel. (Refer to 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - INSTALLATION).
(4) Reconnect the battery negative cable.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SEAT BELT TENSIONER,
SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE SYSTEM CAPACITOR TO DISCHARGE BEFORE
PERFORMING FURTHER DIAGNOSIS OR SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Position the instrument cluster to the instru-
ment panel.
(2) Reconnect the instrument panel wire harness
connectors for the cluster to the connector receptacles
on the back of the cluster housing.
(3) Position the instrument cluster into the instru-
ment panel.
(4) Install and tighten the four screws that secure
the instrument cluster to the instrument panel struc-
tural support (Fig. 5). Tighten the screws to 4 N´m
(31 in. lbs.).
(5) Reinstall the cluster bezel onto the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - INSTALLATION).
(6) Reconnect the battery negative cable.
8J - 16 INSTRUMENT CLUSTERDR
INSTRUMENT CLUSTER (Continued)

CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE
MAIN BEARING FITTING
SELECT FIT IDENTIFICATION
The main bearings are ªselect fitº to achieve proper
oil clearances. For main bearing selection, the crank-
shaft position sensor target wheel has grade identifi-
cation marks stamped into it (Fig. 36). These marks
are read from left to right, corresponding with jour-
nal number 1, 2, 3, 4. The crankshaft position sensor
target wheel is mounted to the number 6 counter
weight on the crankshaft.
INSPECTION
Wipe the inserts clean and inspect for abnormal
wear patterns and for metal or other foreign material
imbedded in the lining. Normal main bearing insert
wear patterns are illustrated.
Inspect the back of the inserts for fractures, scrap-
ings or irregular wear patterns.
Inspect the upper insert locking tabs for damage.
Replace all damaged or worn bearing inserts.
MAIN BEARING JOURNAL DIAMETER
(CRANKSHAFT REMOVED)
Remove the crankshaft from the cylinder block(Re-
fer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT
- REMOVAL).
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 (0.002
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.
Install the crankshaft into the cylinder block(Refer
to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT -
INSPECTION).
Check crankshaft end play.
CRANKSHAFT MAIN BEARING SELECTION
(1) Service main bearings are available in four
grades. The chart below identifies the four service
grades available.
Crankshaft JOURNAL SIZE
SIZE mm (in.)
MARKING
9R9Size 63.488 - 63.496 mm
(2.4995 - 2.4998 in.)
9S9Size 63.496 - 63.500 mm (2.4998 - 2.4999
in.)
9T9Size 63.500 - 63.504 mm (2.4999 - 2.501
in.)
9U9Size 63.504 - 63.512 mm (2.5001 - 2.5004
in.)
Bearing size
Bearing
CodeSize Application
Upper Bearing
A.2.443 - 2.447
mmUse with crankshaft
size9R9
(.0961 - .0963
in.)
B2.439 - 2.443
mmUse with crankshaft
9S, T9
(0.960 -.o961
in.)
C2.435 - 2.439
mmUse with crankshaft
9U9
Fig. 36 MARKINGS ON TARGET WHEEL
1 - REARMOST CRANKSHAFT COUNTER WEIGHT
2 - TARGET WHEEL
3 - MAIN BEARING SELECT FIT MARKINGS
DRENGINE - 3.7L 9 - 43

CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDUREÐCRANKSHAFT 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 (0.002
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 position sensor target wheel has grade identifi-
cation marks stamped into it (Fig. 62). These marks
are read from left to right, corresponding with jour-
nal number 1, 2, 3, 4 and 5. The crankshaft position
sensor target wheel is mounted to the number 8
counter weight on the crankshaft.NOTE: Service main bearings are coded. These
codes identify what size (grade) the bearing is.
MAIN BEARING SELECTION CHARTÐ4.7L
GRADE SIZE mm
(in.)FOR USE WITH
MARKING JOURNAL SIZE
A0.008 mm
U/S63.488±63.496 mm
(0.0004 in.)
U/S(2.4996±2.4999 in.)
BNOMINAL 63.496±63.504 mm
(2.4999±2.5002 in.)
C0.008 mm
O/S63.504±63.512 mm
(0.0004 in.)
O/S(2.5002±2.5005 in.)
INSPECTION
Wipe the inserts clean and inspect for abnormal
wear patterns and for metal or other foreign material
imbedded in the lining. Normal main bearing insert
wear patterns are illustrated (Fig. 63).
NOTE: If any of the crankshaft journals are scored,
the crankshaft must be repaired or replaced.
Inspect the back of the inserts for fractures, scrap-
ings or irregular wear patterns.
Inspect the upper insert locking tabs for damage.
Replace all damaged or worn bearing inserts.
Fig. 62 Main Bearing Markings on Target Wheel
1 - REARMOST CRANKSHAFT COUNTER WEIGHT
2 - TARGET WHEEL
3 - MAIN BEARING SELECT FIT MARKINGS
Fig. 63 Main Bearing Wear Patterns
1 - UPPER INSERT
2 - NO WEAR IN THIS AREA
3 - LOW AREA IN BEARING LINING
4 - LOWER INSERT
DRENGINE - 4.7L 9 - 133

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)

CRANKSHAFT
DESCRIPTION
The crankshaft (Fig. 23) is of a cast nodular steel
splayed type design, with five main bearing journal-
s.The crankshaft is located at the bottom of the
engine block and is held in place with five main bear-
ing caps. The number 3 counterweight is the location
for journal size identification.
OPERATION
The crankshaft transfers force generated by com-
bustion within the cylinder bores to the flywheel or
flexplate.
REMOVAL
NOTE: This procedure can be done in vehicle. How-
ever the transmission must be removed first.
(1) If crankshaft is to be removed while engine is
in vehicle remove the transmission. Refer to 21 -
TRANSMISSION/TRANSAXLE.
(2) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(3) Remove the oil pump from the rear main bear-
ing cap (Refer to 9 - ENGINE/LUBRICATION/OIL
PUMP - REMOVAL).
(4) Remove the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(5) Remove the timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(6) Identify rod bearing caps before removal.
Remove rod bearing caps with bearings.CAUTION: Support crankshaft before removing
main bearing caps. failure to do so will allow the
crankshaft to fall damaging the crankshaft.
(7) Using a suitable jack, support the crankshaft.
(8) Identify main bearing caps before removal.
Remove main bearing caps and bearings one at a
time.
(9) Lower the crankshaft out of the block.
(10) Remove and discard the crankshaft rear oil
seals.
(11) Remove and discard the front crankshaft oil
seal.
INSTALLATION
(1) Clean Gasket Maker residue and sealant from
the cylinder block and rear cap mating surface. Do
this before applying the MopartGasket Maker and
the installation of rear cap.
(2) Lightly oil the new upper seal lips with engine
oil.
(3) Install the new upper rear bearing oil seal with
the white paint facing towards the rear of the engine.
(4) Position the crankshaft into the cylinder block.
(5) Lightly oil the new lower seal lips with engine
oil.
(6) Install the new lower rear bearing oil seal into
the bearing cap with the white paint facing towards
the rear of the engine.
(7) Apply 5 mm (0.20 in) drop of MopartGasket
Maker, or equivalent, on each side of the rear main
bearing cap (Fig. 24). DO NOT over apply sealant or
allow the sealant to contact the rubber seal. Assem-
ble bearing cap to cylinder block immediately after
sealant application.
Fig. 23 Crankshaft with Journal Size Identification
Fig. 24 Sealant Application to Bearing Cap
1 - MOPARTGASKET MAKER 5 mm (0.20 IN.) ON BOTH SIDES
OF REAR MAIN CAP
9 - 252 ENGINE - 5.9LDR

²Installing an insert into the tapped hole to bring
the hole back to its original thread size.
STANDARD PROCEDUREÐHYDROSTATIC
LOCK
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
When an engine is suspected of hydrostatic lock
(regardless of what caused the problem), follow the
steps below.
(1) Disconnect the negative cable(s) from the bat-
tery.
(2) Inspect air cleaner, induction system, and
intake manifold to ensure system is dry and clear of
foreign material.
(3) Place a shop towel around the fuel injectors to
catch any fluid that may possibly be under pressure
in the cylinder head. Remove the fuel injectors (Refer
to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL
INJECTOR - REMOVAL).
(4) With all injectors removed, rotate the crank-
shaft using the crankshaft barring tool (PN 7471±B).
(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 fuel injectors (Refer to 14 - FUEL SYS-
TEM/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 50
N´m (37 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) Disconnect engine grid heater harness at grid
heater relays.(3) Disconnect electrical connections from rear of
alternator.
(4) Recover A/C refrigerant. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE).
(5) Raise vehicle on a hoist.
(6) Drain engine coolant (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(7) Remove engine oil drain plug and drain engine
oil.
(8) Remove fan/drive assembly. Refer to Section 7
± Fan/Drive Removal
(9) Remove radiator upper hose.
(10) Remove upper fan shroud mounting bolts.
(11) Disconnect the coolant recovery bottle hose
from the radiator fill neck and remove bottle.
(12) Using a 36mm wrench, remove viscous fan/
drive assembly. (Refer to 7 - COOLING/ENGINE/RA-
DIATOR FAN - REMOVAL).
(13) Remove cooling fan and shroud together.
(14) Disconnect heater core supply and return
hoses from the cylinder head fitting and coolant pipe.
(15) Raise vehicle on a hoist.
(16) Remove transmission and transfer case (if
equipped).
(17) Disconnect exhaust pipe from turbocharger
extension pipe.
(18) Disconnect engine harness to vehicle harness
connectors.
(19) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).
(20) Remove flywheel/flexplate.
(21) Remove transmission adapter
(22) Disconnect A/C suction/discharge hose from
the rear of the A/C compressor.
(23) Lower vehicle.
(24) Disconnect lower radiator hose from radiator
outlet.
(25) Automatic transmission models:
(26) Disconnect transmission oil cooler lines from
in front of radiator using special tool #6931
(27) Remove radiator. (Refer to 7 - COOLING/EN-
GINE/RADIATOR - REMOVAL).
(28) If A/C equipped, disconnect A/C condenser
refrigerant lines.
(29) Disconnect charge air cooler piping.
(30) Remove charge air cooler mounting bolts.
(31) Remove charge air cooler (and A/C condenser
if equipped) from vehicle.
(32) Remove damper and speed indicator ring from
front of engine.
(33) Disconnect engine block heater connector.
(34) Disconnect A/C compressor and pressure sen-
sor electrical connectors.
9 - 290 ENGINE 5.9L DIESELDR
ENGINE 5.9L DIESEL (Continued)

(c) Apply a durable top coat to the outside of the
repair area.
(28) Tighten the front cab mounting bolt to the
FESM bracket to 81 N´m (60 ft. lbs.).
(29) Install the stabilizer bar. (Refer to 2 - SUS-
PENSION/FRONT/STABILIZER BAR - INSTALLA-
TION)
(30) Install the front bumper. (Refer to 13 -
FRAME & BUMPERS/BUMPERS/FRONT BUMPER
- INSTALLATION)(31) Install the wire harness and ground strap if
previously removed and install the bolt.
(a) If necessary, re-drill and tap the ground
strap mounting hole
(32) Install the front wheelhouse splash shield.
(Refer to 23 - BODY/EXTERIOR/FRONT WHEEL-
HOUSE SPLASH SHIELD - INSTALLATION)
CAUTION:
All welds should conform to DaimlerChrysler vehicle engineering process standard ªPS 9472º.
WELD PROCESS SPECIFICATIONS
WELDING PROCESS FLUX CORED ARC GAS METAL ARC (MIG)* SHIELDED METAL ARC
(STICK)
Material Thickness3.7 mm to 4.2 mm 3.7 mm to 4.2 mm 3.7 mm to 4.2 mm
Electrode TypeLincoln Electrical Co.
Product #: NR-211 MP
(Do Not Substitute)AWS ER70S-3
(Do Not Substitute)** AWS E 7018
Electrodes Size Inches0.045 Tubular 0.035 Solid 3/329
Electrode Stick Out3/89- 1/291/29- 5/89N/A
PolarityElectrode9-9
Work Piece9+9Electrode9+9
Work Piece9-9Electrode9+9
Work Piece9-9
Shielding GasSelf Shielded 75% Ar
25% CO2Self Shielded
Gas Flow RateN/A 25 - 35 CFM N/A
Wire Feed Speed
(inches per minute)110 - 130 Vertical Down
70 - 90 Flat & Overhead245 - 250 Vertical Down
210 - 225 Flat &
OverheadN/A
Approximate Amperage
Vertical110 - 130 175 85 (3/329Diameter)
Flat & Overhead70 - 90 155 90 (3/329Diameter)
Voltage15-18 19-20 N/A
Direction of Welding
VerticalVertical Down Hill (only) Vertical Down Hill (only) Vertical - Up Hill (only)
Flat & OverheadFlat - Push or Drag Flat - Push or Drag Flat - Drag
*First choice - Gas Metal Arc Welding Process:
Butt joints - apply two layers (passes) of weld metal.
First pass should only fill approximately
1¤2the thick-
ness. Vertical position welds - maintain electrode
wire at leading edge of weld puddle while traveling
down hill to produce maximum penetration into the
sleeve. These techniques work for FCAW as well.**E7018new electrodes may be exposed to the
atmosphere for up to ten hours with no harmful
effect. Reconditioning schedules should come from
the manufacturer.
13 - 10 FRAMES & BUMPERSDR
FRAME (Continued)